08/17/2026
From a foam board pattern to a set of .090 leg boards.
For things like this foam board is a far better material than template paper for a mock up pattern.
After making my pattern I transferred it to .090 aluminum sheet, stomp sheared it and finish cut the intricate parts with the Beverly Shear.
I oversized the upper edge by 1-1/4" so I could double brake a 5/8" lip to reinforce the top.
After that I TIG welded the seam where the break meets and buffed it smooth with a Rol-Loc disc for a clean look.
Once I got them home, I did some final trimming with my Marston shears, transfer scribed the 3/16" mounting holes from the carbon floor and drilled them out.
I like to use the 3/8" thick clamp on rollbar brackets to reinforce the top of the boards to the dash bar it helps preventing them from flopping around and coming loose in the event of a crash.
I mark the location with a Sharpie, drill the location and file it square allowing the reinforced lip to fit the bracket exactly to size.
1/4-28 hardware is used to attract the brackets to the boards at the outer ends of each slot to minimize deflection.
After that it's dimple die reinforced,, lightened, check for fit one last time, marked for a leg blower hole and then blown apart to be powder coated.
Not sure if I'm going to use pads in this one yet.
Anyway, that was my slow Sunday after chilling with my lady and rearranging some furniture this morning.
Danny