Part One.

Create a Template

1.      With a 2” by 3” tag of metal, mark out a half profile of a top.

2.      Cut out the material with a grinder or vertical band saw.

3.      Smooth out the contours.

4.      Cut off a piece of CRS (Cold Rolled Steel) about 4 inches long

5.      Chuck the work piece and progressively remove the material until the top contour matches the template.

6. This will take time as you  will need to remove an abundance of material from the upper and lower regions of the top in order to leave a large center diameter

7. The trick to successfully completing this assignment is periodic flipping of the component, so remove material from one side until it is about 3/4" (.750") then chuck that end. Remove material on the other side to the 3/4" diameter then go back to the first end and go to about 3/8" and so on.

8.      A level four requires that the template and top match contours by .060”

     A level three is .125”

    A level two is .250”