Coin Returns

One of the projects I needed to do to get R2 looking good was to make the coin returns.  I took some scraps left over from all the panels I punched out of the skins and made 3 pieces with the correct dimensions.  I then took a "nibbler" tool I got at Harbor freight and punched out the square hole.  I was worried but the nibbler worked great!

Below are the 3 panels - one with the hole cutout.  I just cleaned up the hole with a file.

I got some very thinn sheet aluminum at the hobby store and cut out the back parts using a pair of scissors.  I bent these to shape and glued them together with good old JB Weld.

Here is the installed parts after wet sanding and then finishing with a scotchbrite pad.