Thanks everybody. I really appreciate the encouragement.
So, I've been been running my 3D printer solidly, turning out all the "padded bits". I've got the ones that surround the doors pretty much done. These were printed in polystyrene, as I typically do. A bit warmer today ( -1° C), so I sprayed some primer on them, then ran in the house and hit them with the hair dryer.
Here they are arranged on a 1:1 CAD drawing:
Something that's been troubling me is how I'm going to bend up the tubular racks seen on both walls. I made up a couple of jigs and tried my first one today. It's not perfect, but I think the technique has promise.
The aluminum block in the center is fixed in place by a couple of screws through the bottom of the plate. The 1/8" rod is held against the block with one of the clamps, then heated locally with a heat gun and bent. The next clamp holds it place and you repeat for the next one, working around the block. The two ends overlap each other. I remove it from the block and cut the overlapping ends flush with a razor blade. The groove in the top of the block is used to align the two ends while gluing.
To get the two 45° bends, I use a second fixture. This is made from a piece of MDF. There is a stop at one end to align the frame to, and then clamped in place with a small piece of aluminum. The nuts in the MDF were pressed into a slightly smaller hole with my vice and secured with a little cyanoacrylate.
I heat the rod again locally with the heat gun and bend over the form and install the next clamp. The last side is heated and bent but held by hand while it cools. The picture below will help:
For the legs of the tubular racks, I made a jig that will allow me to drill a 1/8" hole exactly in the middle of the rod. Here's a test piece:
That's it for now. Thanks for looking in.
Peter