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Sheetmetal parts from a flat pattern: Reverse design

Bluchip
Bluchip Member Posts: 26 ✭✭
in Community Support
I've searched most tutorials and discussions. I can't seem to come up with an answer for the project I have at hand. I hope there is a reasonably simple solution!
I am recreating a part from an old drawing. I have the flat pattern layout and THEN the bend instructions. I can recreate the flat pattern in a sketch but then how do I create the sheet metal part by bending a few areas?
I can get close by creating a sheet metal model by using the center portion of the sketch less "fingers" which get bent@26° along a straight line :
I then used flange tool to add excessively large flanges at the bend lines and at the correct angle and bend radii:

And then extrude remove the outer finger profile using the outer portion of sketch followed by finish sheet metal tool:
This all LOOKS great but as you experienced folks know, it is too large in finished OD as it was extruded with the flat pattern sketch with no consideration for material consumed in the bending.
Any thoughts how to best go about creating a sheet metal part when you know what the flat pattern is but not the finished part? If we skip sheet metal tools altogether, how best to create a solid?
thanks in advance for any advice!

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