Basically, you clamp the metal in a vise with a piece of hard wood, bang on it with a hammer until there's a 90-degree angle. Then flip it on its side with another piece of hard wood and bang some more. Then you've got a U-shaped piece. At that point, drill the hole in the end. Then, clamp it back in the vise with a triangular piece of wood inside it (the two ends of the U are in the vise jaws) and bang yet more. At this point, you've got the basic shape. After that, drill and ream the hole for the bolt and grind the square corners off.
Unless you're a much better metal worker than I, I don't see how you'll make it look as nice as the diagram in the plans. Still, once it's bolted into place on the spar, I think mine will look pretty good. When they're just sitting there, however, they're not closed up tight on the end. I can get them to close up, but then the end where the nut will pull is not flat.
By the way, the info pack is not clear at all about the material you need for these. Aircraft Spruce sent me stainless tubing. Huh? After looking at the materials list (which is in the info pack), I could see their confusion. The plans spell out the material needed for these. Make sure that's what you get.
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