Guys, inspired by Anakin Starkillers design, I wanted to re-do my Yuma lever, at least to make it a more accurate size. I tried this by hand and the amount of cutting discs I used... the amount of hand filling and grinding, was a lot!
I didnt use a Jig Saw because of how small it is, and tried to guesstimate using that one blurry picture and Dan's model.
Used some square aluminum stock about this size and sliced it up! It is more parallel than it looks, metal files leave lots of facets that confuse light in pictures
Two skinny pieces of threaded rod act as glue pins.
And I MADE MY FIRST BLANK HOLE.
The original lever had a piece of 1/4 20 rod in there, so I drilled it out and used a piece of round bar, lathed in a drill press, to slide in there. Really, I got it very close and used a Vice to crush it into place. Dremel and hand file and voila!
Glue is curing, will post finished pic soon