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This is a real timely post for me. Yesterday, I made several pieces of corrugated metal for a building project. I experimented, using evergreen plastic corrugated panels. I cut a piece of the plastic into a 3 inch square, and then cut same sized squares from an aluminum cooking pan. I flattened the ribs in the pan by rubbing a piece of wood over them, then I taped the aluminum on top of the plastic square. Then I used the end of a welding rod ground to a point, and dragged the pointed rod down the metal  forming each groove guided by the ribs of the plastic. I lubricated the pointed rod with dish washing liquid. That seemed to help the rod slide down the metal. It was really a simple process and the end result is good. As you create each rib, the aluminum wants to curl up, so I flattened it back out and taped it down to hold the grooved metal in the plastic ribs. Taping the metal down, keeps it seated in the plastic groove and assures that the ribs are uniform. I first used the evergreen plastic with .100 rib spacing but it is too wide for O scale. I then picked up a piece with .060 spacing and it is just right. The plastic sheets are $6.00-$7.00 for a 6 inch X 12 inch piece. You can cut any size piece for your "die" and can make a whole lot of corrugated tin in a short period of time. The cooking pan I used was $1.25 at Family Dollar.

I added some images. The first picture shows the size difference between .100 spacing and .060 spacing. I know the pieces look a little ragged. They are going to be weathered so they can be old like me!

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Last edited by spudder

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