Started a grill block - upper only at this stage
Before we start, upper grill is open on both sides.
Measurements using a corn-flakes packet, the only large enough card piece we have (as opposed to cardboard).
Cutting out of coroplast (aka Correx here in the UK). Note that I have the tubes (grain ?) going top to bottom instead of left to right. This is because the curve is mainly side to side so its easier to bend this way.
Left is a mirror of the right.
First try with the pieces in place. Need to fix them more securely and see what happens. Will get some bolts and large washers tomorrow.