I thought the double sidewall construction was going to end up with it being somekind of a battery using some sort of magical separator. :person_facepalming:
Seriously though, bending them together in a sandwich might be the way to get the bends to coincide. ???
What gauge metal?
Cut copper sheet to size and bend into the body shape, maybe use a forming block.
Clamp the inner copper to the outer when formed with a little solder paste and torch it.
Thanks for the input. Thats kinda what I’ve been thinking, CRX. As far as materials, I’m thinking of ordering some copper strips online. Probably something like 2mm x 15mm for the inner strip and 1mm x 18mm for the outer strip.
I recently tried the After Dark for some tailcaps and they came out great. To take full advantage of the service, you need to tailor your design for it so that the traces look good (and potentially using copper for labels instead of silkscreen):