This is a good time to check the clearance of each panel, so we'll close the amprack with the trim panel sides in place. This shot shows the amprack three-quarters of the way open. We use Bosch jigsaws exclusively since they are very accurate, and these Bosch T101BF blades are excellent for cutting ABS plastic and wood. A flat brace is cut to fit between the two trim panel sides and glued in place using CA glue (superglue).
The top of the trim panel must be filled in between the two amps, and 1/8" ABS plastic is perfect for this. Two thin strips start the filling process. These are CA glued in place. Using a vice, slowly shape the ABS in several places to get the desired bend. As long as the bend is less than 10 degrees or so, it won't crack. Heat can also be used to bend ABS, but it can often lead to a warped panel. This close-up shot shows how the thick CA glue builds up a bead in the seam between the two ABS pieces, minimizing the amount of body filler needed later.
Finally, to create threads in the plastic for the bolt to grab, use a 10-24 tap and slowly tap through the hole. With all of the top panels glued in place, the basic panel is finished. Next we need to smooth out the overall shape. The amprack trim is held in place with two bolts drilled through another trim panel that we already built. A countersink bit is the first step in this process.
A flat-head bolt is screwed into place using an Allen-head wrench, and it holds the panel in place while sitting flush with the surface. This area will later get an insert to cover the screw head. An angle die grinder is used to round the edges and grind down the glue beads. The bent panel fits the curve perfectly; now it can be glued in place.