Now that we've covered the basics, the same bends in the first post can also be done using an MDF hammerform. Here the MDF is stacked to allow the flange to be folded downward.





The first three layers are aligned and screwed down, then the 18 ga CRS and "locking" layer of MDF is screwed down, through the entire pile using 4" long screws.








Flange width marked and trimmed. The corners are cleaned of any burrs that may promote cracks to form by using a 3/4" dia drum sander.








Straight bends are worked with a low crown hammer to start the profile........





........and as the corners tighten, this was the most effective stretching device. Repeated overlapping rows made short work of the stretching..





....and the door skin hammer was used around the perimeter to "sharpen" the bends...














This same process, through use of various router bits to shape the opening, can be used to add bead details around the opening (stainless trim relief), or a radius rather than a sharp bend, etc. The possibilities are only limited by your imagination.