Fold down panel and shelf

Has anyone built the panel and shelf like Jon from Homebuilthelp  did in archive file #9.  I'd like to hear suggestions about how to size the aluminum panel shelf.  I think using an undersized piece of cardboard use a compass or 2" piece of wood to scribe the line.  Transferring these lines to a larger piece of cardboard adding 3/4" all the way around and then copy to an even larger piece of aluminum.

I'm open to suggestion.

Thanks in advance.

David

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