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Belt sander and angle grinder with flap disk

I’m not a painter, but it might be worth getting a couple of these Trailer fenders for $19 to practice on. https://m.northerntool.com/shop/tools/product_200649345_200649345

I'd use MDF or plywood for the back piece, cut kerfs for 3/8” deep for the shelfs, and insert strips of 2” x 1/8” aluminum.

Install a rivnut then put a screw in. Looks like they’re available in 6-32 and up.

To seal it and prevent cracking, look at what they do with chain saw carvings. This may help. https://forum.woodcarvingillustrated.com/forum/woodcarving-illustrated/woodcarving/chainsaw-carving/1124420-preserving-a-chainsaw-carving

Get plastic containers like these... https://www.amazon.com/dp/B07SYC9TX9/?tag=atomicindus08-20 glue, screw or pop rivet the lids to the bottom of the container. Snap as many together as need to make a log.

I’d anneal it first. Mark the bend line with a marker heat the backside until line fades mostly away, and let it cool

How about slicing a tube lengthwise, 1” conduit would be close to what you want.

I think you could build block to hold pieces of bandsaw blades (maybe sharpen the edge like a knife) to the shape you need. Then use a press or a hammer to cut the pieces. I’ll try to post a picture of what I mean later.

On my cabinets I used 4” x 3/4” plywood top and bottom rails for the back.l and left the rest of the back open.

Don’t drill... google ‘wire wrap arrowhead’ instead.

Best way to find a great project for your roller is to sell it. You’ll have a great idea before the buyer pulls out of your driveway.

Mc master Carr has 1” socket head screws with 3/4” hex. You could turn down the treads to fit inside the 1” tube, secret with a couple plug welds. Bushing May by better than a bearing, less likely to rust.

Ron Covell makes it look easy

One of these may work to mold a cast/splint. https://www.amazon.com/dp/B00WW8KIRI/?tag=atomicindus08-20 https://www.amazon.com/dp/B004MFLU4Y/?tag=atomicindus08-20

See if you can find someone with a 3D printer to make a trim piece to cover the cut edges.

Look here for several methods to raise the top. https://www.customcylindersintinc.com/article/understanding-camping-trailers-roof-lift-systems

Can you use a regular grommet and put a piece of fuel line over the brake cable where it goes through the grommet?

The link I posted above provides dimensions and weight of different materials they hold.