05-02-2012, 01:25 PM
Ingenious solution, Kurt. 
I checked Evergreen to see if they offered strip styrene with a hexagonal cross-section (sand it to remove half) and I also thought that a two-corrugation jig, with the corrugations hand-formed, could serve as a form for pressing the ends from heavy foil, such as the kind used for throw-away roasting pans. You'd form two corrugations, then move the foil up, one corrugation at a time, to do the rest of the end. The second corrugation on the jig would then be used only as an alignment/spacing aid. The formed aluminum ends could then be attached to heavy sheet styrene sub-ends using contact cement.
Wayne
I checked Evergreen to see if they offered strip styrene with a hexagonal cross-section (sand it to remove half) and I also thought that a two-corrugation jig, with the corrugations hand-formed, could serve as a form for pressing the ends from heavy foil, such as the kind used for throw-away roasting pans. You'd form two corrugations, then move the foil up, one corrugation at a time, to do the rest of the end. The second corrugation on the jig would then be used only as an alignment/spacing aid. The formed aluminum ends could then be attached to heavy sheet styrene sub-ends using contact cement.
Wayne