Making aluminum coin returns

I made my own set of 3 coin returns from left-over aluminum from the Sherell skins plus some aluminum step flashing from Home Depot.

I got the drawings from the Astromechs site. I printed them out 100% and marked the scrap aluminum. The benefit of using the scrap from the skins is that it's alread bent to the correct radius.

I have made JPEG versions of the drawings available for download, including my template for the inset piece:
left rear coin return JPG
right rear coin return JPG
left front coin return JPG

To cut the square openings, drill a 1/2" hole then use a nibbling tool to make the cuts. It's tedious, but worth the time.




Then for the inset part I cut a piece from thin step flashing and bent it to shape. I cut a paper template and used spray-tack to hold it into place (spray the paper, not the metal).


Cut it out, then peel off the paper. A straight edge is handy to get all the bends just right.


I have a template file for the inset piece if you want it. Just email me.


It's then JBWelded into place and clamped.