Hello SolidWorks forum !

I am using SW2014 to re-construct side plate sections of a vintage recording console, I have drawn out the sections, and I have tried to use a custom form tool to produce the relevant half shears used to mate with the respective ISEP rail profile.

But, every time I use the form tool, the stopped face punch side is correct, but the 'extruded' section is deformed incorrectly.

Pic of ISEP profile with punch construction dimensions.

Punch Tool.

Punched panel with correct indentation (face side).

Punched panel from extruded side ( deformed Half Shears).

Punched panel showing indentation marks, with distorted outlines (extruded side).

Actual Half Shear - punch side.

Actual Half Shear - Extruded side.

ISEP Profile.

ISEP Profile mating with Extruded Half Shear.

Any ideas ?

I've searched the forum, found this - https://forum.solidworks.com/thread/31687?q=half%20shear , lots of useful info, tried some suggestions, but still can't get it correct !

Best,

Steve