A bit of an odd request for help with this one...
I have a caravan which has a damaged alloy panel, the damage area rather than being flat, is corrugated with horizontal lines about 1mm deep every 6mm. I have filled the damage with car body filler and now I am trying to recreate the corrugated profile by scraping it using the undamaged corrugations as a guide.
I attempted to make a suitably profiled scraper, but my level of accuracy using a file simply wasn't up to the job. The scraper needs to be about 12" long, to be able to span the entire damaged area and around 3mm thick. Idea was to let the filler set then scrape it down to profile.
I have a nice big piece of the corrugated panel as a sample.
My original idea was to cast a rubbing block out of the body filler on the spare section of alloy, greasing the panel to enable it to be released, then using the cast block with some wet and dry to recreate the profile.
Another idea was to wrap some round bar with wet & dry and try to use that to recreate the corrugations one by one.
So far I have got the damage in a very rough profile by applying filler over the damage, covering it with cling film then using a 6mm rod as roller to span across to the undamaged area and roll the surplus filler up the panel. Once the filler has set, the cling film just pulled off.
I'm not sure of what I am asking here, other than for help with suggestions.