Here's an example using the bolt detail that's cast-on many plastic models. The cast-on grab iron was shaved off, then holes drilled beneath the bolt detail, with the "legs" of the wire pushed through the holes. I bend-over the ends of the wire inside the shell, then apply ca, also from the inside.
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Where there's no cast bolt-head detail, you need to select the proper-size nbw castings, drill holes for them and cement them in place. When the cement has hardened, drill holes above, below, or beside, depending on your prototype, the nbw, then install the wire grabs.
If you
absolutely have to have that flattened section, there are at least two ways to accomplish it. The first is to form the wire grab iron from brass, but only the part that will be visible when it's installed. At the point where a regular grab iron would enter the hole in the body shell, bend the "legs" outward to each side. Next, with the grab crossways in an open vise, and supported by the out-turned legs (hanging across the opening between the jaws of the vise like a "U"), set a piece of metal atop each leg, in turn, at the point where it bends to form the "U", and strike the metal lightly with a hammer. This will create a flat spot. Use a knife, Dremel tool, and/or file to shape each flattened area, then trim them to proper length. Now, drill each flattened area to accept a suitable-diameter wire (which will represent the bolt - you're on your own here for the nut/washer part of the equation
), solder the wire in place, leaving enough to bend over when inserted into the body shell. You may be able to file the solder to a rough approximation of a bolt head, then trim the visible end of the wires to length. Finally, drill corresponding holes in the body shell, inserting, bending, and cementing the wire as outlined before.
An easier way is to install the nbw castings in the proper places, then cement short lengths of .010"x.020" styrene strip in place to represent the flattened areas. Drill the holes for the wire part of the grab iron, and install as outlined.
Grandt Line offers a wide selection of nbw castings, with different style washers (round, cupped, square) and in various sizes. For grab irons, the 3/4" size are probably most appropriate. Detail Associates has wire grab irons with a sprue of plastic 3/4" nbw castings included.
Wayne