I copied the aluminum skin method substituting birch door skins. The skins bend pretty well, but in the end I decided to steam them to help with the bending.
The Process:
Mark the beginning and end of the end caps with a pencil.
Glue blocks in place to provide a stiff surface to bend against.
Fill in with fiberglass instillation.
Then make several rectangular parts 11.5"X52". Starting from the outside bend the skin and mark the lines to on the ends to cut. To make the cut I used a compound miter saw.
Make a simple template from scrap door skin, mark the edge with rivet hole spacing.
Pre-drill rivet holes, lower edge and upper end only.
Install the part to the lines, have a helper hold, I ended up going solo; purchase an air-driven riveter, well worth the money. I used between 300-350 rivets.
In tight spots use an Olympic rivet for added holding power.
Left side, 3 panel on:
All the skins on, wires are for lights:
Lights installed, Repurposed tambour parts with spalted alder sides, installed next to closet over bed.
Linear Mode
