op4wd1
Member
Chop saw with abrasive disc on plate steel to a little over size needed, stack 4 plates together tack each end. Drill hole for bolts for bars. Transfer pattern to top piece of steel. Take 4 1/2 grinder with cut off wheel cut around pattern leaving about a 1/16 to 1/8" heavy from the pattern. Arc on tabs was cut using 3" hole saw in drill press. Also used die grinder to blend arc on tabs that hole saw didn't get. After all roughed out the lathe I have has a milling attachment I then cut straight sides to line of pattern. Curved areas formed on bench belt sander. Then grind tack welds apart and you have your matching pieces. Simple as pie just takes a couple of days to complete.