Here is the other side and I'm holding on the smaller piece with my vise. With my bolt and nut nice and tight, my work pieces didn't move and I was able to drill my holes with no problem. Now it's time to make the lock pins that will go into those 1/4" holes.
 

At the beginning I thought about using rivets to hold things together, like it was originally. But after thinking about it and doing some testing on the plastic, I decided to use flathead screws instead. What I did was countersink the four holes for some 10-32 screws.
 

Here is what the screws look like in place. These will work better because they are flush with the plastic surface and don't have a bump on them like rivets have.
 

If you look close, you can see the small hole for the lanyard.
 

The arrows are pointing to the area the long pins will be welded to (with the use of a flat piece of steel that goes across those two pieces). And then the long pins will be welded to that flat piece.

Road Trip

I took this assembly over to Stefanie's salon to see how it looked so far. Well it's a good thing I did because if I welded those long pins (from the other headrest) to this one like I wanted to, it would've sat too low. I measured the amount I needed to adjust for and now it's time to make an extension.
 

I'm going to use four pieces of steel to make my extension out of. The size that I want to end up with is 3/4" wide but the two bottom ones are oversize. Time to do some machining on those pieces.