By the way,
"I made it at TechShop"
Step 1: Digital Model
1. The mounting holes were traced on to paper, giving an accurate "mold" of the needed parts.
2. Using Autodesk Inventor digital models were created using measurements from the paper traces
3. The digital models were exported from the inventor sketch as a dwg to CorelDRAW for printing
4. The initial prototyps were printed on standard 8.5"x11" paper and compared to the sketchs
5. Steps 2-4 were repeated until I was satisfied with the models
Step 2: Prototyping
All of the prototypes were made from scrap material laying around. For the first prototypes cardboard was used.
After every test piece small adjustments to the digital model were made and a new prototype was quickly cut out with the laser.
After everything had been perfected using cardboard, final prototypes were made from scrap acrylic plastic.
The final prototypes were then test fitted on the car to see if any last changes needed to be made.
Step 3: Creating The Part
For the final part 1/4 steel scrap was used (it was thin enough for the application, sturdy, and free).
The water jet did a fantastic job at cutting out the parts, after about 1/2 an hour of set up and cutting, the inner and outer pieces were done.