So my MG TC is missing its battery box lid. Very easy to make rectangular piece of plate, but it is secured by 2 wire clamps.
So I had some blanks cut. I left the tab a little long to allow enough meat to form the indentation.
So I made a
press tool to press the form into the blank. I calculated the wire diameter plus 2 x material that gave me the size of the slot. I then clamped 2 of those 25 x 25 solid bars together and drilled a hole of that size material thickness away from the joint. With a little bit of filing it left me with the perfect die..
A drill the size of the wire turned into the press part. I used the softer shank of the drill for this to prevent any shattering due to the pressure.
And this is the result. Material is 1.6mm mild steel. It pressed like butter.
And additional material remover to look like the final part.