You want details? Okey doke.
We checked the wood out against the wheel and tried a little finish to see if we'd be close. I had a rough measurement of the length(27"), height(1 5/7"), and thickness(1"), and Mike did a rough cut of the piece. He then ran it through his router to give it a rounded curve on each side, giving it a slighty squarish hemispherical shape when viewed from either end. I took the two pieces home and did the detail fitting. This entailed shaping the ends to clear the weather stripping on bothe ends of the door. I also had to do some shaping of the driver's side piece because the door isn't perfectly straight across the top.
Once shaped I considered how to mount and what sort of trim to put on it - chrome screws, a black strip matching the Nardi, or the rivets that I finally settled on. The rivets meant that the mount would have to be pretty much permanent and would have to take place before finishing. I drilled the 3 mounting screw holes in each piece and then went over to Mike's where he used his drill press to countersink the mounting holes and the dummy rivet holes in between. I had previously measured where to drill the holes for the side window mounts and had purchased metals sleeves to hold the windows on. Carey Hines sent me the nice aluminum ferrules for the window holes. Mike used his drill press for those as well.
I finished the back side of the pieces with something he call "waterlox". I have no idea where he gets it, but it's a sealer and stain that really brought out the beautiful grain of the wood. That took about 4 coats, with some sanding with a finishing pad between each. I then mounted them with long machine screws and nuts. They I glued in the heads of the rivets with Gorilla Glue. I had to do quite a bit of sanding on the aluminum rivets to get them flush and shiny. Then I applied three coats of waterlox. Mike had just discovered a new finish that he recommended as a top coat, so I drove the car over there and we applied two coats of this stuff who's name escapes me. I'll call and ask if anybody wants it. It dries in less than an hour to a really smooth nice finish that you can apply another coat to. Finally, after letting the last coat dry for 24 hours I put all of the remaining trim on the door.
The shaping is specific to a Beck, but I'll take some pics of the specifics if anybody want some.
