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Matt, On your deck baffles, measure from the deck to the blade tip and that should be good for the baffle width. I would go to a local fab or welding shop and have them shear some 1/8" to that width. The sheet of steel is 48" so if they sheared three pieces that would be enough with some left over. Then you can take a car tire or something large and round as a bending jig to get your radius. I would leave about a 1/2" space between the blade and baffle. You can use the extra 1/8" to make the tabs, if you have a vice to bend it in. If not 1/16" will work. As for welding in the house, I don't think anyone would recommend that.


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