42 - Rear Seat Backs

While looking ahead in the plans, I decided to take care of assembling the rear seat backs. This is a quick and easy section that doesn't have any dependency on work done so far in previous sections.

I began by by cutting the 1/8" and 1/16" 3/4"x3/4" angles to length. I then shaped the ends of the longer angles and rounded the apex of the shorter angles as outlined in the plans.

Seat back angles cut to length and shaped as required. Hole positions were marked along two of the shorter angles that will nest at the top of the rear seat backs

I then deburred the edges of the rear seat backs, and marked hole positions for drilling using measurements in the plans. With a 3D printed drill guide, I drilled 1/8" holes at the marked locations along both rear seat backs. I also used the drill guide to drill the 1/8" holes into the marked short angles that will attach to the top of the rear seat backs.

Rear seat backs deburred and marked for hole drilling

Using a 3D printed template as a drill guide to accurately drill holes at the marked locations. This enabled me to skip the step of center punching each hole location prior to drilling

Rear seat back and angle 1/8" holes drilled

Close up of rear seat angles showing drilled holes and rounder apex.

Apex rounding was done carefully and evenly using the 1" belt sander and the deburring wheels

I then clamped the angles to the rear seat backs and match drilled the skin holes into the angles. Along with the bottom angles, I positioned the bottom hinge half that I had previously fabricated while working on the rear seat floors in position so that the holes would also be match drilled through the hinge.

After match drilling all holes to 1/8", I reamed them to #30.