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5500 Stabilizer General
sparendcapchannelsusecuttingpatternstofindthecutoffsneeded_small.jpg markwidthofchannelflatpatternperdrawing_small.jpg drawcuttinglineusingstraightedge_small.jpg cutchannelstrips_small.jpg thecutstripscomeoutofthecutoffslikethis_small.jpg usecuttingpatterntofindwheretogetpartshelpstocheckthemoff_small.jpg marklengthofeachpartonstripsifalittleextracanbeaddeddoit_small.jpg usesquaretokeepchanelblanksaccurate_small.jpg markedeachpartwithlengthandnamesoitcanbefoundlater_small.jpg
allofthepartsareaccountedforcutthechannelblankstrips_small.jpg startsmoothingwithscotchbritewheelonlythelongsidesneeditnow_small.jpg finishsmoothingwithscotchbritewheelbyhandendwillbedonelater_small.jpg horizontalandverticalstabilizersparandendcapchannelblanksdone_small.jpg markchannelsforbendingperdrawinglineupfirstflangebrakebend_small.jpg lineupsecondflangeinbrake_small.jpg finishbendingchannel_small.jpg completedstabilizersparsandendcapchannels_small.jpg cutoutendcapformblocktemplate_small.jpg
foundagreattemplategluesprayonplywoodtostickontemplate_small.jpg sticktemplateonplywoodanduseittoguidethecutting_small.jpg usingdisksandertotrimtoline_small.jpg beverycarefulsmallpiecebringsfingersveryclosetorouterbit_small.jpg keepyoureyeontheworkandfingersoutofthebit_small.jpg placeformblockinendcapchannel_small.jpg lineupblockwithendofchannel_small.jpg markaroundtheendoftheformblock_small.jpg pencannotreachallthewaytothesideflangewillgettothatlater_small.jpg
marksideofchannelatdottedlineonformblock_small.jpg thisiswherethesideflangewillbetrimmedto_small.jpg markedandreadytotrim_small.jpg trimaroundtheendandcutthroughtheverticalflange_small.jpg cuttheverticalflangeaboutonequarterinfrontofthemarkontheside_small.jpg thisisthebasicroughshapeweneedbendradiustransitiontothefront_small.jpg trimofftheexcessflangecurvingdowntothemarkontheside_small.jpg puttheformblockbackintomarkthefinalshapeofthefront_small.jpg nowthepencanreachallthewaytothesideflange_small.jpg
shapethefronttotheextendedline_small.jpg frombottomshouldhaveasmoothcurveallthewaytothesides_small.jpg sandingdiskfinishesthisinsidecorner_small.jpg usingsandingdisktomaketheonequarterradiusonsideflange_small.jpg switchtoscotchbritedisktosmooththeedges_small.jpg finishinsidecornerswiththesmallhalfroundfile_small.jpg thisisthefinalshapenoticehowthebendradiustapersintothefront_small.jpg insideviewofthetransitionoftheradiustothefrontofthepiece_small.jpg slideformblocktooneeighthinchfromthetipofthecurve_small.jpg
placeclampblockonequarterinchfromthetipofthecurve_small.jpg clamptogethersecurely_small.jpg readyforformendcaparoundformblock_small.jpg startformingfromtipworkslowlymanylighttapssonottokinkedge_small.jpg keepmovingaroundthetipasitcurvesaroundtheformblock_small.jpg blendthecurvearoundthetipintothebendradiusofthechannel_small.jpg ittakessometimebutisagreatwaytorelaxbyhammeringsomething_small.jpg aboutthispointturningitonitssideworkedbetter_small.jpg theblendingofthebendintothesideisgoingwell_small.jpg

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