I did a rough trim of the flange that was going to be attached to the firewall. I could sense that this might not work out so I didn't take time to make the cut perfect.

And here was the beginning of the end for this albatross. When I started to bend the curvy tabs to the required 99 degrees to match the cowling angle, the rotten welding job came back to bite me in the fanny. The weld started cracking. At that point, the game was over and it was time for a new approach.

This is the nifty flange I made with the plan to attach about 11 little angled brackets to attach the whole contraption to the firewall. Keep reading to learn why this was just another exercise in honing my fabrication skills!

Insert picture of flange idea.

A friend suggested that I could attach my really nifty new flange with small angle brackets. I made one and decided it could work. I then drew another 11 brackets on a piece of .063" aluminum bent to a 90 degree angle.

Purely by chance, as I started making the cuts to fabricate the little brackets, I realized that the once-stiff-as-a-board angle became very flexible. Hmm... Why make the tabs separate? Why not make it a single piece, thus eliminating the process of [re]attaching the angles to the flange.

After a RIDICULOUS amount of time spent with a cut-off wheel, needle files, Scotch-Brite drums, and emory cloth, this is the basic piece. Very bendy. Goooood.