Back at it today, and decided on a different tack on the corner problem. I'd cut one piece putting the grooves to the inside and wasn't happy with it, and had just about decided to buy a couple of pieces of aluminum sheet stock that I could form, but I decided to try putting the grooves on the outside of the curve and I liked the result better. I needed a 90 corner at the bottom, fanning to a curve at the top matching the body. After a bit of finagling I used a 1.75" bottom, 1.25" flat at the top, and 7.5" of curve.
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Took the fence off of the radial arm saw to give me more length for the cut, set the blade ~3/32" above the table and cut the grooves. I'd drawn the corner curve on a piece of matt board stock, transferred that to a piece of 2x6 stock and used the inside curve to form the corner.
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After tacking the piece to the upper corner and a small 90 block at the bottom I flooded the grooves with resin, added a layer of cloth and slopped on more resin and let it dry.
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As Gomer used to say, "Surprise, Surprise, Surprise!" It seemed to work!
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Not sure yet, but I may add a 1" strip of plywood to my corner piece to overlay the back panel and cover any gap, or I may just leave it alone and let the foam & material hide the gap.
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All in all, I'm happy with the corners. Got the other side cut & glassed. Tomorrow I'll trim it to fit, then drill both corners & the body for clips, then get the door panels mounted to line up. As jb likes to say, another duck in the row!
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