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Metal Shaping A Rear Fender

Discussion in 'The Hokey Ass Message Board' started by jhnarial, Sep 12, 2010.

  1. jhnarial
    Joined: Mar 18, 2007
    Posts: 410

    jhnarial
    Member
    from MISSOURI

    I'm a rookie metal shaper and I'm going to shape a rear fender. I shaped one some time back but I did a lousy job on rolling the fender lip.

    So for this one I am going to make a simple buck out of 3/16'' round bar and some bondo.

    I'm making the buck just so I can use it for a hammer form for the fender lip and flanges. This is way overkill for a one off fender but if it works it will be well worth the three hours it took to make it.

    Started off by forming the wire to the inside of the fender. It does not have to be perfect. You actually want up an 1/8'' from the fender so the bondo will be able to flow underneath the round bar.

    test run 359.jpg

    Make sure you will be able to get the wire form out from the fender. I actually recorded a flange and then cut it out so I did not have to make this a two piece wire form. Next I remove the wire form.

    test run 360.jpg

    While it was removed I waxed the inside of the fender heavily, the wax will act as a release agent for the bondo.

    test run 362.jpg

    Then apply the bondo and let it set up.

    test run 363.jpg

    Then I tapped it with a rubber mallet and it released from the fender.

    test run 364.jpg

    Next I will be taking a flexible shape pattern from the fender. Some might be able to shape this fender with a simple paper pattern but for me information is the key, so the more information I have the better off I will be.
     
    Last edited: Sep 12, 2010
  2. hotcoupe
    Joined: Oct 3, 2007
    Posts: 509

    hotcoupe
    Member

    subscribed, thanx for taking the time to document this for us.
     
  3. limp
    Joined: Jun 18, 2007
    Posts: 122

    limp
    Member

    very interesting, i'll be watching this one
     
  4. I always like your threads.....Thanks....
     

  5. jhnarial
    Joined: Mar 18, 2007
    Posts: 410

    jhnarial
    Member
    from MISSOURI

    Flexible shape patterns are about the best tool I know of for metal shaping. Understanding how to make and read one, plus having the understanding of in and out of arrangement. You can shape just about any panel.

    Most people use a low stick masking tape(overlapping 1/8'') for their first pass. Low stick masking tape cost about seven dollars a roll, I have found if you buy the cheapest tape you can find it will more then likely be low sticking.

    test run 369.jpg

    Next it will be lapped with a layer of strapping tape(overlapping 1/2 the width of the tape)

    On both the masking and the strapping tape lay it down as flat as possible. Let it over lap if it wants to.

    test run 372.jpg

    After pulling the pattern from the fender kill the tackiness of the tape with baby powder.

    Now that I have my pattern and the buck I have more then enough information to take on this task.

    test run 373.jpg

    Next I will start shaping some metal.
     
  6. Irrational Metalworks
    Joined: Feb 5, 2007
    Posts: 589

    Irrational Metalworks
    Alliance Vendor
    from DFW

  7. bct
    Joined: Apr 4, 2005
    Posts: 3,098

    bct
    Member

    looking good! i'm watching/learning, so thanks!
     
  8. jhnarial
    Joined: Mar 18, 2007
    Posts: 410

    jhnarial
    Member
    from MISSOURI

    I will post more on the shaping process as I go along but the key is if it fits the pattern


    test run 374.jpg


    and you put it into its proper arrangement, it will fit perfectly every time.


    test run 382.jpg

    It's usually a fight for me getting it to fit the pattern but if you are persistent you can usually get it.

    Next I will show how I shrink and stretch the metal.
     
  9. Francisco Plumbero
    Joined: May 6, 2010
    Posts: 2,531

    Francisco Plumbero
    Member
    from il.

    This is excellent thanks.
     
  10. tinmann
    Joined: Nov 11, 2005
    Posts: 1,588

    tinmann
    Member

    Watching............. waiting................waiting.................waiting...............




    thanks for posting this, by the way.
     
  11. hasty
    Joined: Jul 5, 2009
    Posts: 1,410

    hasty
    Member

    Thanks, helpful thread
     
  12. jhnarial
    Joined: Mar 18, 2007
    Posts: 410

    jhnarial
    Member
    from MISSOURI

    I will be leaving for a metal shaping get together, I am taking the fender for my project. I will be leaving Thursday and returning on the 24th.

    I will post my progress then.

    Take care
     
  13. blt2go
    Joined: Oct 27, 2009
    Posts: 551

    blt2go
    Member

    you magnificent bastard!!! i have been laying paper and cardboard templates for years and wondering why my "new" pieces have to be so heavily hammered to meet contour. great thread. i'm subscribed.
     
  14. studhud
    Joined: Jan 6, 2006
    Posts: 1,403

    studhud
    Member

    Johnny your awsome take some pics at the meet for us that cant go
    Thanks Dave Hitch
     
  15. jhnarial
    Joined: Mar 18, 2007
    Posts: 410

    jhnarial
    Member
    from MISSOURI

    You can pay to go to seminars or by videos or read all you can on the internet, and you won't even come close to how much you will learn by attending one of these gatherings.




    Here are some of the key things I learned.
    • How to work a panel correctly all the way to the edge of the panel.
    • I learned how shape reverses.
    • I learned how to gas weld.
    • I learned how to read a oil can, You have to know how to read it before you can fix it.

    Anyways back to the fender, There was so much going on I forgot to take pictures of the actually shaping. All I did was make it fit the pattern. when I work the metal to the pattern, I start off with shrinking on the stump. I try to get all of it in one round but I never do. Next I place the the pattern on the top and start feeling for air underneath the pattern. Then I stretch the metal up until it fits the pattern tight. The metal will tell you what it wants, If you get a buckle in the metal that is it's way of telling you it needs some more shrinking.



    After I got the four panels shaped I clamped them to the buck so the panels would be in arrangement and I could scribe my lines.



    MVC-157F.jpg



    I tacked it up with a mig. One of the vendors there was Jim Spradly, he sells Henrob Torches. I have always been curious about them. I have seen them demonstrate them at different events. It was hard for me to believe they would cut like a Plasma and weld like Tig. To my surprise it does cut like a Plasma and it welds even better then a tig. The weld is so soft and easy to work, and it was easy to use.



    If there is any interest in Henrob torches PM me and I will give you Jim's number.



    MVC-403F.jpg



    MVC-404F.jpg



    MVC-405F.jpg



    MVC-423F.jpg



    We worked the weld as we went but after it was welded I cleaned it up and ran it through the plashing hammer. I usually just do this with a hammer and a dolly.



    MVC-467F.jpg



    MVC-468F.jpg



    MVC-478F.jpg



    It's still in the rough in stage​



    MVC-457F.jpg



    Next I will clean it up with a shrinking disk to take care of any flaws.
     
  16. Streetwerkz
    Joined: Oct 1, 2008
    Posts: 718

    Streetwerkz
    Member

    looking good, keep it up!!
     
  17. bct
    Joined: Apr 4, 2005
    Posts: 3,098

    bct
    Member

    wow. nice to see a skill gained while havin fun.
     
  18. PonchoJohn
    Joined: May 1, 2009
    Posts: 238

    PonchoJohn
    Member
    from Fresno, Ca

    Dude, you're my new hero! Nice posting!
     
  19. scootermcrad
    Joined: Sep 20, 2005
    Posts: 12,374

    scootermcrad
    ALLIANCE MEMBER

    Yep! This is VERY cool!! Thank you for sharing this! I've been wondering about flexible patterns like that...
     
  20. fab32
    Joined: May 14, 2002
    Posts: 13,985

    fab32
    Member Emeritus

    I think I speak for many when I say "you can never get too much of posts like this". Keep it coming.

    Frank
     
  21. Dyce
    Joined: Sep 12, 2006
    Posts: 1,917

    Dyce
    Member

    Johnny my ass hurts, I've been kicking it all week for not going to Kerry's. Nice work on the fender. You should haul it up to Dan's in October:)
     
  22. jhnarial
    Joined: Mar 18, 2007
    Posts: 410

    jhnarial
    Member
    from MISSOURI

    I really wish I could Jeff. I had a great Time with Dan and Jessie and was wishing you could have came. They spoke highly of you.
     
  23. jhnarial
    Joined: Mar 18, 2007
    Posts: 410

    jhnarial
    Member
    from MISSOURI

  24. Irrational Metalworks
    Joined: Feb 5, 2007
    Posts: 589

    Irrational Metalworks
    Alliance Vendor
    from DFW

    Nice job Johnny! Your skills have come a long way.One of these days I will make it to Kerrys meet, hopefully the next!
     
  25. rockable
    Joined: Dec 21, 2009
    Posts: 3,427

    rockable
    ALLIANCE MEMBER

    That is really nice work and I agree that we can't have too many posts like this one. This is true ART!
     
  26. jhnarial
    Joined: Mar 18, 2007
    Posts: 410

    jhnarial
    Member
    from MISSOURI


    Thank you Tim

    I'll be there next year hope to see you there. It was a great bunch of guys and gals
     
  27. dragster dude
    Joined: May 21, 2010
    Posts: 194

    dragster dude
    Member

    you are the man thats some awsome work
     
  28. michael037
    Joined: May 26, 2005
    Posts: 320

    michael037
    ALLIANCE MEMBER

    Thanks for taking the time to show us the steps required to carry out the work you have done, and the pictures to make it easier to understand. I have always wondered how you make and use a flexible pattern, and now have half an idea on how to do it.
    Thanks again
    Michael
     
  29. tdoty
    Joined: Jun 21, 2006
    Posts: 821

    tdoty
    Member

    I was hoping Lori got pics of me making that big rear section of the fender....no luck. The good news is Johnny managed to make something out of it ;) I went to grab it one morning and it was gone -Johnny was hard at work finishing it up!

    Kerry's meet was great! I didn't win the long distance award, but I drove down from Illinois to join in. Wish ya could have made it, Jeff!

    Tim D.
     
  30. jhnarial
    Joined: Mar 18, 2007
    Posts: 410

    jhnarial
    Member
    from MISSOURI

    It was fun wasen't it Tim

    Thanks for the help
     

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