1/8 inch thick aluminum cut to shape and filed with a bend radius.
The nose of the flat metal sheet is formed first then put in the blocks.

Use a small hammer with edges filed smooth. I covered the head with gas pipe tape.
I also covered the metal with the tape for 3/4 of the forming but remove it for the final part.
Then file the lip edge down to about 1/8 inch and Scotch Bright it.