I always enjoy reading thru the tech week posts, there is always such a wide display of talent and ingenuity. This is the first time I had a solution that I thought worthy of, most likely not winning anything but at least sharing. This post is for those of you, who like me have limited space and power for tools and need to make a one off complex shaped patch with a somewhat disposable tool. One day I hope to have more room, but until that time you have to make do with what you do have. So this is what I came up with... Problem: 52 Studebaker truck passenger side inner step to cab floor threshold was rusted out in the most unfortunate of places. Solution: Make a plywood die to stamp out a piece that can then be finished by hand. First I made a paper pattern of the desired shape. Then I trimmed the existing threshold of the rusted and whole filled metal, to leave only a solid edge which will be overlapped by the new piece. With the pattern I cut the plywood shapes and sanded the desired radius on opposite corners of the two pieces. I then attached each of them to a piece that was the size of them fitted together to make a top and bottom die. To press the dies together I drilled two holes to the outsides of the desired size finished piece for all-thread. I finished off with some steel flat stock to help stiffen the dies. (If I ever need to do this process again I would put all-thread at each corner with steel plates that covered the full size of the plywood.) I then placed the dies in my bench vise and started tightening the three compression points until the dies bottomed out. With the starter piece stamped out I worked it with a slap hammer and various mandrels until it fit. It still needs a little grinding finish work, but I believe it was a success.
I'd been thinking about something like that for a while, but never gotten around to doing anything about it. My guess is you've switched a lot of light bulbs on in people's heads with this one.
I've used 2-2X4s to make the bend from floor to toe board , but never would have thought something as complicated as your patch panels could work---helping each other is what this site is about--GOOD JOB!!!!!
Great low cost option. Guys seem to think they need to spend their life savings to build a car, this shows the best tool is the one between your ears.
Great Thread !!! Post more as you build. Good Old Common Sense still goes a long way when you need it most................... Jeff
Extremely clever approach, well done. Did you need to compensate for the thickness of the sheet metal when building the dies? You may wish to trim and fit with existing sheet metal after forming the part to butt weld rather than lap joint to avoid trapping areas for future rust, depending if this is possible given the location of the patch.
looks good. not too many people realize that being a good wood worker is a important part of being a good metal worker. Making a good accurate Buck / jig / hammer form or wood press is all part of restoring cars. I would suggest using a few small screws to attach your metal down to your lower plate. This will prevent any slipping of the metal. Just use small enough screws that you can easily plug weld the holes later. I think your finished product will benefit.
I've said it before and I'll say it again, I'm honored and fortunate to have a friend and club brother that can think as well as have great design and fabrication skills. I'd like to say how surprised I am at this tech tip......but I'm not.
Excellent idea. Thanks for sharing. I didn't see it said, but in theory you could also use a hydraulic press and some plate steel. I know some don't have a press, but if you did....
I worked at a shop where we routinely made metal dies similiar to this and used either a hydraulic press or even an arbor press. Great tech post. Really illustrates how to this nicely.
I would have taken it out in the driveway and ran over it with my pickup, lol. I'm not trying to be a smartass, it probably would work well.
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