Trimming the cover and fabricating the lip

Cover is finally trimmed to size. This was done by removing very small amounts of material then "trying for size" a number of times. Because the shape is curved this took some time to get right.

Using the card template from before, the pattern was transferred to sheet steel. Note the datum marks were also transferred.

This gave a panel size identical to the hole so I needed to add an edge to this.

The final panel was then trimmed...

...and the edge joggled to give the lip that was needed.