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Tape a sheet of old plastic dropcloth over the opening.
Use a drymarker to rough trace opening
Cut out plastic in shape of opening
Test fit, mark + areas and - areas with arrows and estimates of distance (1/8", 1/4")
Draw shape with adjustments on coroplast
Cut out with exacto knife
Test fit, mark + areas and - areas with arrows and estimates of distance (1/8", 1/4")
Draw shape with adjustments on coroplast
Cut out with exacto knife
Test fit, mark + areas and - areas with arrows and estimates of distance (1/8", 1/4")
Maybe by the third try I am lucky enough to get very close to the right shape.
Trace out shape on plywood (MDO, paper coverered, sign board)
Cut out with jigsaw
Sand
Screw down plywood pattern to work table
Put some turns of masking tape on the pattern
Stick coroplast on the pattern
Use a router to cut out coroplast
Test fit part, mark + areas and - areas with arrows and estimates of distance (1/8", 1/4")
Sand pattern appropriately
Try again, maybe repeat one more time, by this time you should be very close and have a good fitting part
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