[Christ]

Originally Posted by freebeard

I picked up the ABS, and a 2nd smaller pieces that should be big enough for a pan from the front valance to the McPherson struts.

So now I'm thinking about flanging the edge of the ABS. You show the edge cut and bent into tabs. Do you think I could heat the edge with a heat gun and hammer/bend it over a form without it cracking? Or crimp it with a hand tool? I'm thinking a 1/4-3/8" continuous edge rather than the tabs. I guess I can experiment on a scrap.

If you put it on a wood table and heat up the entire edge with a heat gun, it will start to fold over on it's own. When this happens, keep a bucket of water and a rag handy, wet/wring the rag and use your hand to force it over the edge into the angle you need and the water will cool it down while you're holding it so that it forms to the angle and won't return to straight.