M16A1 Handguards

[HOOKED ON HISTORY]

A man after my own heart.
I just came in from 95 deg. F 100% humidity heat building a set of light brackets for a truck that I could have bought for $40.
Sometimes you just need a challenge.
I have contemplated your mission although never tried it. Perhaps build a supporting form with cardboard or something like it to the rough shape of the "tooth". Coat it with some type of release agent and build up with bedding compound or HB weld? File /dremmel to final shape?
That's as far as I got with my brainstorming.
P.S.
I should have bought the brackets.