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Let's see some sheet metal shaping

Discussion in 'The Hokey Ass Message Board' started by jhnarial, Sep 16, 2008.

  1. redoxide
    Joined: Jul 7, 2002
    Posts: 594

    redoxide
    Member
    from Scotland

    DSCF5688 (2).JPG pure function no frills freehand dress up for my buddies 27 T :)

    DSCF5430.JPG DSCF5446.JPG DSCF5458.JPG
     
    Last edited: Aug 15, 2019
  2. I started messing around with a piece of scrap on my English wheel the other day. It turned into a compound reverse curve clock. IMG_3807.JPG
     
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  3. MP&C
    Joined: Jan 11, 2008
    Posts: 2,347

    MP&C
    Member

    So we've been blocking out epoxy primer, it sure is nice to be able to rotate the car where you need it instead of sanding upside down on the bottoms of drip rails.

    [​IMG]

    But then you walk past the Driver's A pillar and see a hole that shouldn't be there.

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    I don't know how I've missed this before. We did have this same repair done to the other side, I guess with the roof damage confined to that same side I must have not thought this side was suspect. Goes to show, check ALL problem areas, especially if issues show on one side.

    [​IMG]

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    Inside the hole has a minimal amount of surface rust, especially for 64 years old. Safe to say the damage was caused by water/dirt accumulation between the center structure (the one we're remaking) and the outer skin. Oh well, it's been a while since I've had a back up and punt moment. Glad this was found before the green kandy went on.
    Starting to make the new replacement for the inside, using 14 gauge cold rolled steel.





    Quite a bit if stretch added for the part to match the original..

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    Rough shaped on the MH19, tuned up a bit with body hammers, punches used as anvils, and various other implements of destruction. Trimmed and fitted:

    [​IMG]

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    [​IMG]


    All ready for welding.…..
     
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  4. MP&C
    Joined: Jan 11, 2008
    Posts: 2,347

    MP&C
    Member

    Tacked using the TIG:

    [​IMG]

    video:



    [​IMG]

    welds dressed:

    [​IMG]

    [​IMG]

    Epoxy primer added:

    [​IMG]
     
  5. MP&C
    Joined: Jan 11, 2008
    Posts: 2,347

    MP&C
    Member

    Now to get our outer patch fabricated.. The corner is going to need a GRUNCH of shrinking.. We started on the Baileigh, but the dies are only going to get us so far. So some tuck shrinking with some heat for persuasion was used..


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    A tipping wheel in the bead roller was used to mark our bend line, and an upper press brake die used as an anvil to hammer the flanges over..


    [​IMG]


    Some hammer action to stretch the corner flange so it will tip the full 90*





    [​IMG]


    I missed some in process pictures here, but various hammers, anvils, punches, and other implements of destruction were employed to give us our basic shape...


    [​IMG]


    [​IMG]


    After a bit of fine tuning, it is trimmed and fitted into the A Pillar...





    ......and the windshield stainless is test fit for good measure..


    [​IMG]


    The finished piece is media blasted (Barton Garnet) so the SPI epoxy primer will have a good bite. The inside is primed as a bit more preventative measure over factory....


    [​IMG]


    [​IMG]


    The flange is quite small compared to what we normally plug weld, so we opted for a .169 drill bit to keep the heat away from the edge...


    [​IMG]


    In order to clean he primer out the inside of our plug weld holes, we flattened and backfaced our drill bit to mimic an end mill....


    [​IMG]


    Does a good job of giving us nice clean metal for a good weld..


    [​IMG]


    [​IMG]


    much better....






    .
     
  6. hasty
    Joined: Jul 5, 2009
    Posts: 1,409

    hasty
    Member

    Impressive...
     
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  7. CoolHand
    Joined: Aug 31, 2007
    Posts: 1,926

    CoolHand
    Alliance Vendor

    These little fiddly patches with huge amounts of shape in them are the ones that always amaze me the most.

    It's hard enough making something like that when you've got something to hang onto and lever around, doing it with a 3" square bit of metal just makes everything harder yet.

    Excellent result, sir.
     
  8. Dyce
    Joined: Sep 12, 2006
    Posts: 1,902

    Dyce
    Member

    Fixing some 31 chevy fenders this week. The front edges were damaged. I made these in the Baker a few weeks ago. 20190923_130056.jpg 20190923_130119.jpg
     
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  9. MP&C
    Joined: Jan 11, 2008
    Posts: 2,347

    MP&C
    Member

    Nice work Jeff!
     
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  10. MP&C
    Joined: Jan 11, 2008
    Posts: 2,347

    MP&C
    Member

    Had some PM's asking to clarify the forming process that I missed getting pics of... Did a couple time lapse videos, first shows the shrinking of the corner. The Vise Grip tucking tool, torch, and hammer is used to get the corner to come down about a 20* angle, then the two flanges were folded, which gives us one big tuck. At that point wide VEE is heated up and the high spots of the flange corner is hammered back into itself. Repeat for the next high spot, until the corner is folded where you want it.



    Here's the corner shrink complete...
    [​IMG]
    Then the barrel end hammer is used to make the joggle creases by using an upper die from our press brake as a post dolly. That’s the basic process.



    If you find the time lapse too fast, you can change playback speed on YouTube to slow things down a bit..
    .

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  11. Dyce
    Joined: Sep 12, 2006
    Posts: 1,902

    Dyce
    Member

    20190925_080748.jpg
    Progress on the left.
     
  12. Dyce
    Joined: Sep 12, 2006
    Posts: 1,902

    Dyce
    Member

    20190925_155245.jpg 20190925_171333.jpg

    I welded the right side in yesterday...
     
    Last edited: Sep 26, 2019
  13. THE FRENCHTOWN FLYER
    Joined: Jun 6, 2007
    Posts: 3,386

    THE FRENCHTOWN FLYER
    Member
    from FRENCHTOWN

  14. MP&C
    Joined: Jan 11, 2008
    Posts: 2,347

    MP&C
    Member

    Nicely done Jeff!


    Picked up a new set of dies for the Lennox for a different shape...

    [​IMG]

    here checked to the sample we were sent...

    [​IMG]

    forming a 19 gauge sample on the Lennox:



    [​IMG]
     
  15. Nice Robert! I did that job by hand with a Masonite buck. Thankfully I was only making patches. I assume you’re getting ready to make a bed floor or some other large panel?
     
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  16. MP&C
    Joined: Jan 11, 2008
    Posts: 2,347

    MP&C
    Member

    A buddy is using a 2008 replacement bed floor to put in a 66 Ford pickup. He has some ribs that stop in the middle and other that change width. So we’re going to make full length beads all the same width as per 1966 out of a newer part.
     
    Last edited: Sep 28, 2019
  17. Dyce
    Joined: Sep 12, 2006
    Posts: 1,902

    Dyce
    Member

    I really like the piece you made for the handle on your Lennox. I will definitely copy that!
     
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  18. MP&C
    Joined: Jan 11, 2008
    Posts: 2,347

    MP&C
    Member

    Here’s a better option Jeff, holes in the plate and either a threaded or clamp on spring pin to lock the position. I just haven’t gotten past the design stage yet....:D


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  19. "Not to be operated by Fuckwits".........I love it!:)
     
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  20. Dyce
    Joined: Sep 12, 2006
    Posts: 1,902

    Dyce
    Member

    Thanks Robert. I'll put that on the someday when I have time list lol.
     
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  21. SEAAIRE354
    Joined: Sep 7, 2015
    Posts: 239

    SEAAIRE354
    Member

    Love the warning sticker going to need several of them for work.


    Sent from my iPhone using H.A.M.B.
     
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  22. MP&C
    Joined: Jan 11, 2008
    Posts: 2,347

    MP&C
    Member

    Flattening and backfacing a drill bit to clean paint off the adjacent panel in a plug weld hole...







    .
     
  23. studebakerjoe
    Joined: Jul 7, 2015
    Posts: 765

    studebakerjoe
    Member

    MP&C would that sticker be from AVE on YouTube?
     
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  24. MP&C
    Joined: Jan 11, 2008
    Posts: 2,347

    MP&C
    Member

    No, I had about 50 or so printed up at Bonehead Graphics...
     
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  25. Ziggster
    Joined: Aug 27, 2018
    Posts: 858

    Ziggster
    Member

    I love watching people make up panels. It is majical to me, and hoping one day I can do something similar. Took these pics at Hershey this week. I believe they are original NOS panels for mid 60's Ferraris.
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    Attached Files:

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  26. Ziggster
    Joined: Aug 27, 2018
    Posts: 858

    Ziggster
    Member

  27. SinisterSleds
    Joined: May 6, 2012
    Posts: 15

    SinisterSleds
    Member
    from MA

    Daytona (yellow) and Dino 246

    Sent from my SM-G950U using Tapatalk
     
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  28. john worden
    Joined: Nov 14, 2007
    Posts: 1,674

    john worden
    Member
    from iowa

    Thanks for the up close detail pics.
     
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  29. Gofannon
    Joined: Feb 8, 2007
    Posts: 621

    Gofannon
    Member

    O/T for the board, but not for this thread. Hippy looking dudes building a Handpan. This guy could do the body work on your car and "tune it up" at the same time. How anybody worked out how to build one of these in the first place is beyond me.
     
  30. Marty Strode
    Joined: Apr 28, 2011
    Posts: 5,526

    Marty Strode
    Member

    I forgot to post pics of the finished Lakester. IMG_3295.JPG IMG_3293.JPG
     
    Okie Pete, bymanr, JOYFLEA and 9 others like this.

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