I'm not sufficiently familiar with the original to notice small differences Scuba, the plan was to get a whole set of detailed pictures of a good original solid deck from every angle, then add dimensions, sheet metal thicknesses, full details of all of the welds, and so forth, so we have a reliable record here of it all, before anyone gets inventive and decides to make them out of Kraft single cheese slices.
How square you can get the corner of the bend depends partly on how thick the sheet is, and mostly on how good the folder/pan brake is, and how carefully you set it up. You probably know all that better than I do. Getting a good job of sheet metal folding is rather easy with a good brake, especially a power-operated one with limit switches, and close to impossible with a little benchtop folder, though I couldn't do it decently with either one.
To me the most important question to resolve is whether the objective is to make them exactly like the original. Of course I'd vote yes, but I'm not going to be making them.
