I use stainless bar, all i do is put a 45 angle on it with a grinder with a soft sanding disc in it, then i make it into a hex shape, finally blend all of them together then polish.


There is other ways of doing this i'm sure but this is just how i did it.

I started off with some 304L 12mm x 6mm stainless flat bar, this will take a radius cold quite easily but any thicker and heat would be needed.





Next i made a rough template in card and clamped the bar in the vice behind a large socket and started tweaking it slowly







This piece was a little more fifficult to do as about 150mm from the end it curves down as well, Again it was tweaked slowly to form the curve, you will find as you bend one way the other will try and straighten out so you will need to go back and retweak.





Once the desired shape was acheived i drilled 3.3mm holes where the holding studs were needed, the pillar drill was setup so to prevent braeaking through the other side, these were then tapped for 4mm stainless grub screws.






Next i started to radius the edges, first i ground a 45 degree chamfer on the edges with a angle grinder fitted with a 40 grit flap disc, I found a worn disc to work best as with a new one it was possible to remove to much metal too fast.








Next i added chamfers either side of the first so ending up with a 50p shape, Then i started to blend & fettle to a smooth radius.










All the sanding will alter the shape slightly but its quite easy to reshape later after polishing.
Next job was polishing so i started with a 80grit on the polishing machine working down via 120, 180 to a final 320, this left a very smooth and shiny surface that just needed buffing with a sisal mop to remove the light scratches and was finally buffed with a cotton stitched mop to acheive a nice shine.







Here it is refitted





I've got a rivet theme going through the car so i then marked out the spacing and drilled 6mm holes for the rivets, the rivets are held from the rear by tiny tack welds, the whole thing was lightly repolished and fitted. The seat material now has to be restretched to fit snugly under the edge of the trim but i will leave that to Tom the trimmer as trimming isn't my forte