Now that Hardway has sold off his inventory and doesn't look like he's planning to commission a second run, I feel I can share my D-I-Y strategy with those of you who still need these pieces. The clips aren't terribly difficult to fabricate from sheet stock and they don't have to be made from spring steel (that comes afterwards). Here's how I made mine:
1. Using tin snips, cut 4 metal strips from 0.022" sheet (or close to that). After cutting, flatten the strips on a hard surface with an autobody hammer. Then de-burr all the cut edges with a file.
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After cutting, flatten the strips on a hard surface with an autobody hammer. Then de-burr all the cut edges with a file. This had yet to be done for the pieces in the photo.
2. Fabricate a forming buck from a small piece of hardwood (softwood won't do). You'll need the buck to form the 'bump' in the closed end. The 'bump' shape is mandatory -- it provides clearance for the stamped flange that runs around the periphery of the vent opening in the hatch outer sheet metal). I used a power sander and a Dremel sanding drum to make my buck. When you're happy with the shape, mark the side edge for the location of the centreline of the hole that you'll need to drill in the clip after you've bent it to shape.
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3. Mount your buck in a bench vise, along with one of the metal strips. The vise jaws should clamp on one end of the metal strip and the buck simultaneously (keeps the metal strip in position during the bending process).
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4. Now shape each strip using, as appropriate, either hand pressure or your autobody hammer (use the flat part of the hammer for the outside bends and the 'pick' end for the inside bend).
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5. Mark and centre-punch the hole center before you remove the finished clip from from the buck. Then, using another strip of wood of appropriate thickness as a backing/spacer piece, slide the shaped clip over the wood and then clamp in some fashion to prepare for drilling the hole. Because the hole has to pass through both the upper and lower leg of the clip, you'll need both the spacer piece and a backing board. It's preferable, but not mandatory, to use a drill press here. De-burr both drilled holes afterwards...
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6. To finish up, give the clips a bit of 'spring tempering' by heating them up with a torch (get them just to start of glowing red) and then dunking them in cold water (sorry, no photo for this step)
7. Here's my end result...
The total project probably took me 3 or 4 hours to complete (making the buck is finicky).
Materials costs were ~ zero.
Best part: The clips worked perfectly during the installation of my vent pieces.