Top Ear Cap Reconstruction
Time to finish extending that upper ear cap to the correct size.
Test fitting the ear cap to get a measurement.
Looks to be a 6mm difference.
The termination of the slanted part is also incorrect. It needs to have a part that’s flat. I have marked the part where it needs to be cut.
After the part was cut, using a hobby saw.
To extend the upper ear cap, I built a form out of a piece of cardboard and some balsa wood. I marked the 6mm extension, and then glued a piece of balsa wood perpendicular to those lines.
I placed the two pieces of the upper ear cap on each side of the extension area, and then used a clamp and another piece of balsa wood to hold it all in place.
I mixed up some bondo, and once it started firming up, I removed the piece from the form.
The view of the front. The bondo actually picked up the ink lines from the form.
View from the side. Once it’s totally dry, I will carve it down to the correct shape.