DD 886 u.s.s. Orleck design process

[FRD]

Again with the two sided tape, this time used to secure the angled aluminum rail to the edge of the work surface.

The square serves as a measured guide, it is said that the human finger can detect a protrusion as small as 1/100,000th of an inch, the two parts match precisely by, "sense of feel".

These aluminum extrusions were chosen specifically for their uniformity and clean angles.

The Mylar is essentially locked into place by a C-clamp at each end.

Next, it will be preheated and then the edge rolled to hit the 90 degree angle of the edge.

[FRD]

So I resurrected a relic from thirty years ago, it's a Conair 1875 hair blow dryer that hadn't been fired up in 30 years, works fine, note the settings, I'll have it on High heat with a minimal fan.

Once the Mylar has been properly heated you will know a distinct glossiness of the heated Mylar, that's when you apply the roller to form the creases in the case.

As the Mylar progresses through the brake one crease at a time, the end result is the formed case.