Just a quick step by step I did in pictures about 1am last night! Apart from the length niggle all four of the ones i've folded so far have come out fine with 2 from the 8 thou sheet and 2 from the 10 thou. The 10 has less of a length issue as the folds were really designed for that thickness so it all ends up shorter.

Tools used, the tweezers are the useful bit for the folds while the sharp knife is vital to get it off the fret without distortion. I recommend a good optivisor or similar to most as my eyesight is still young enough to do it without.

No I wasn't using the digest as a cutting mat .

Fold 1 - right angle

Fold 2 - small overfold

Fold 3 - right angle

Fold 4 - right angle

Fold 5 - overfold

Folds 6 and 7 - right angles form the end shape

fold 8 - right angle to close the loop and give you the correct shaped lever guard

To finish you can pin the hole at the top and push the stay through the solebar. Then the other stay needs forming in a z so that it meets the w-iron correctly.

Compare it against my prototype shot here

This BR standard has been lying around for a few years now and its picking up bits along the way. You can tell its an early one as I left the plastic brake gear on and didn't even replace the safety loops! Its now got my new tie bars (a lot thinner than i've managed to cut strip those) and some of the new brake lever guards. I'm making up the levers at the moment.

Let me know if the pictures portray the sequence ok or if I should add arrows. Its obviously easier if you have the piece in front of you to visualise the fold lines but I do want to fix that length issue before I production these. Once its right its right for most wagons!