RBD, really the cut is not as hard as it looks. Truthfully, I never thought it could be done, but I haven’t messed one up yet. I tried a miter box one time and ruined two bodies before I went this way.
Look in the new contest forum and see for yourself… I had a teaser thread up on it since the first of the month. The sign-up starts the first of March and the contest starts in April.
Good question on how to do the screws up. Drilling holes in the side I suppose is out of the question. My first problem would be how to get the holes in the right position so the two halves stay aligned in all positions. My first thought is (dont know how to make it work) is the plastic plug type clips they hold dashboards and grills in these days so that the two halves press together. I no doubt know you will come up with some sort of black magic. Looking really good.
Detents for a position and a stop? Gotta keep from twisting the wire too much too right? A detent or two for position points and a stop at straight and 90º so it stays within that short pivoting range will keep the wire intact. Hopefully. Otherwise, it’d take a continuous positive/ground rotating connection between the 2 plates.
A nylon locking nut will keep the screw from loosening or tightening up.