another progress made:
the most difficult and tiring phase: chucking away (or sanding) place for the metal roller. the metal roller will be used to fold PE parts that are held under the plastic one.
now, i cant stress this enough in this phase:
YOU MUST use protective gear such as respiration mask and goggles! very little bits of plastic will fly in every direction, and some plastic powder so protect yourselves!
first, i continue some work on the plastic roller. i cut three to 24 CM long, in the method described above. then, i place one roller on the large cutting board, mark the holes and drill away. after that, i install the plastic roller with screws, discs and wing nuts, place the metal roller and mark it's borders with a sharp knife. then, using the more coarse sanding bit of my dremel. i have sanded just a bit at start; just to get approximate depth for the metal roller. after that, i have sanded in up and down motion to the entire length of the borders.
Note: this phase is tough, and the outcome is not all that accurate and nice. the metal roller sits "ok" in its place. not tight as i had wanted, but it's ok.
after that, i have cleaned all the plastic that got stuck in the way.
drilling holes in the cutting board:
a snug fit!
marking the metal roller's borders:
metal roller in place:
testing it with academy's merkava MK4 PE set: