I promised myself that I'd show the bad as well as the good. Not everything goes to plan or works perfectly first time, so here's an update with a couple of things that haven't quite worked.
I've been working on this gap in the roofline which is a complex form with a twist - not a flat plate. It's on both sides and I don't want to build it up with formers as I did with the one further forward.
I measured up the profile and made a copy for either side in resin.
Unfortunately the resin is far too brittle to use for this and one snapped (and was glued) as you can see.
So, I printed some out in PLA filament instead. The one on this side is almost there - but the profile is a little off.
Plus - the one for the other side had some printing errors and isn't fit to use.
I'm printing up a second set with an adjusted profile - hopefully these will fit better.
As well as that, I tested the lighting in the seat restraint bars and found that despite my earlier testing (where I got lucky) these micro LEDs have a definite front and back - meaning that one side of the bar will be lit far better than the other. The only real solution is to put two in there, back to back.
That's a problem, because I've glued all of the single ones in place. I'm working to produce one finished one to make sure it'll work, then do the rest. I have to straighten out every restraint, drill out the LED and wiring (destroying the glued-in LED in the process) and threading two in there.
In this shot you can see that there are two LED lamps in there. I'm also strengthening the T bars with a rod inside, and a hole drilled in the main bar. I can't braze these joints - they're too close together so I have to glue them.
Here I'm making swivelling clamps that I'll attach the curved pad to. Hopefully this part will go to plan.