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Thank you for all the advice gentleman. I'm heading out this morning to look at a heavy belt / disk sander that needs to be rebuilt (inexpensive and can grind at 90 deg.). As suggested, I'll just take my time, building with weld, grind, etc. If need be, I'll use the contour from the other side and make a pattern. I'll post a picture of the finished product it's sorted out..
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