I sawed
and sanded the aluminum shapes using the cardboard template, bent
them by hand around a piece of steel pipe. The aluminum is quite
soft after annealing. Aad welded all the pieces together and hammered
a more rounded shape into the wide side of the wedge.
When all
4 manifolds were completed we had spent about twice as many hours
as we had estimated so we decided to leave the grinding and polishing
to Ernst, I just glassbeaded the parts before sending them to
him. I hope he will send us some pics when they are mounted on
his bike!