A really good source for thin metal sheet is the tubes used for foodstuffs like tomato puree and garlic paste.
Empty the contents into a dish without rolling up the tube then use a craft knife to cut off the 'neck' at the top and the crimped end at the bottom then split the tube and wash it in detergent.
The foil is much thicker than kitchen foil and holds it's shape well when embossed, formed or bent.

Here's another option. When you buy those plastic bags for trash and such, some of them come with the paper coated wires (twist ties). Just lay flat and white glue one side to stiffen them up and paint them up. Works good for doors and overhead tin sections. You can bend them slightly to incress the wave in them before gluing. I got a whole shoe box from a friend years ago and have'nt even put a dent in it yet. All different sizes available. If anyone want some to try out , let me know.

Thanks guys. The aluminum tape sounds like a good idea. I did the fold over method because you can scratch it and damage it and expose the 'fresh' surface underneath...

The only problem I've had with kitchen foil though was the glue I was using. There wasn't a huge surface to glue it onto, as well as I was using thin superglue. Possibly the gel type CA glue or even 2 part epoxy might work better.

Hi Austn, congrats again for your stunning dio

To glue metal foils you can use:

Micro scale metal foil adhesive



here a tutorial about how to use it
http://www.britmodeller.com/forums/lofiversion/index.php/t13996.html

or you can use

Eberahrd faber "Easy leaf" glue (which I actually use, because microscale product isn't imported in Europe).



Probably you can also use Acrylic glue (gator) but to be honest I have never tryed. 2 parts epoxy glue or CA gel could produce some unaesthetic "bubbles" under your aluminum sheet. Liquid CA glue is hard to handle with those thin foils

I know you are looking for much narrower corrugations than this

https://armorama.kitmaker.net/forums/154936

for your roller shutters, but I thought this might give you an idea of a tool you could make your self using plastic card of a reasonable thickness.

If you have a paper cutter in A 4 or A 3 size (the type with the roller blade, not the guillotine type), you could run the blade over the plastic sheet pressing the blade as deep as required leaving a v groove.

Mark two pieces of tape with the exact spacing of the grooves you require.

Tape them on the underside, one at each end of the runner guide that holds the cutting blade so they sit on top of the plastic with the spacing marks showing under the clear runner and beyond the blade line when the sheet is fed under the runner.

The first groove cut will mark the plastic and it can be moved in line with the spacing marks.

Repeat the mark and move until there is enough for the purpose or indeed a full card size.

If need be, use an appropriate file or shaped scribe to improve the depth, curve and profile of each or alternating groove to match the desired profile by lightly dragging along the groove.

Either use the plasticard as is, or better still, use this sheet to emboss the tin foil on to using tooth picks or specialist card embossing tools.

Remember to take account of the thickness of the foil to be used when gauging thickness and spacing of the desired profile.

You could make different gauges to suit different scales or just to simulate variations in roller shutter sizes and keep them stored safely for use as needed

Maybe laborious, but once done is yours as needed..

Hope this gives food for thought.

Good luck

Nige

does it have to be metal or plastic? if not look at cardboard boxes. the outer layer of paper is easily peeled away and the inner layers are corrugated. it may take some time, but it is strong and easily glued and painted.
just a thought

reb