Beginning hatch replication

Form block

Working the aluminum around

Pattern for steel hoop around pilot

The starting point

Heated red hot with torch

Heating

Then hammered around

Guides

Coming around

Finally finished

Scorched

Frame coming along

Fully assembled

Frame on aircraft

Frame on aircraft

Rolled hatch for new skin pattern

Copied over to aluminum

Roll, back drill, cleko...

Done!

Clekoed on bench