Fabricating a reflector for inspection of the BSW

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

What to obtain 

1. Aluminum plate: 300 mm (11.8 in) (W), 150 mm (5.9 in) (H) and 0.5 mm (0.02 in) (D) or more
   NOTE: To fabricate the plate easily, we recommend that the plate should be 0.5 mm (0.02 in) thick. If thinner, the plate may be curved easily. If thicker, it will take longer to fabricate the plate.
2. Protective gloves
3. 300-mm (11.8 in) long scale
4. Knife
5. Adhesive tape

1. Align a scale along the scribed line.
2. Hold the scale securely. Use it as a guide to make a V-groove on the plate with a knife.
3. Repeat the process above approximately 20 times to deepen the V-groove.

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

4. Bend the plate slightly to check that the plate can be bent sharply along the V-groove as shown below. If no, the V-groove is too shallow. Repeat step  3.
5. Bend the plate several times to cut it.

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

1. Use three of four plate pieces. If the piece is covered with a protective film, do not peel off it yet.

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

2. Place the plate pieces and apply adhesive strips together as shown below. When the plate pieces are covered with a protective film, apply the strips on the non-covered surface. (Peel off only one side of films when both sides of the plate pieces are protected)
   NOTE: To make a triangular pyramid, clearance between the plates should be 0.5 to 1.0 mm (0.02 to 0.04 in).

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

3. Apply an adhesive strip on the edges to assemble the triangular pyramid as shown below.
   NOTE:

   • Apply adhesive strips on the outside of the panel as the inside reflects the radar wave.
   • When protective films are applied on the inside, peel off them.

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.