Making a not so ordinary panel
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  1. #1
    Full Time Metal Junkie ProMetalShop's Avatar
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    Making a not so ordinary panel

    Hi Folks
    Sometimes just cutting a slot in a panel to go around an exsisting part just isn't enough, and begins to look like every other panel.
    I had to fill in and area behind a grill to feed more air towards the radiator.
    They are commonly known as baffles ! !
    So I started out with a piece of aluminum ( 3003 H14 ) which is rather soft and nice for shaping.
    This is the hood latch brace I need to get around, notice the half circle I have drawn is reference.



    Now I need to stretch the area inside my reference mark .





    With repeated trips back and forth to the beater bag and wheel I making the area deeper and a bit more defined.



    Now I am smoothing the edges and the flats to get rid of the walnuts my hammer left being from stretching.



    The slapper is a great tool for this job.



    My next step was to cut out the slots that fit by the support.



    Now I need to deepen the inside area.



    Thanks Steve
    Shaping Metal Is Often Easier Than Shaping Minds

    http://chevylegends.com/forum/index.php

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  3. #2
    Full Time Metal Junkie ProMetalShop's Avatar
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    Re: Making a not so ordinary panel

    Now back from the bag to the wheel I am starting to show some progress.



    I have to work my edges to make them a bit more crisp and at the same time making the rest of the panel lay flat.



    After a trial fit I realized I needed two deepened areas to make the fit more comfortable.





    Well this is as far as I got so I will continue tomorrow ....

    Last edited by ProMetalShop; 03-04-2010 at 20:51.
    Thanks Steve
    Shaping Metal Is Often Easier Than Shaping Minds

    http://chevylegends.com/forum/index.php

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    Official RnS Addict THE VIKING's Avatar
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    Re: Making a not so ordinary panel

    Very nicley done Steve and thanks for posting

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    Re: Making a not so ordinary panel

    superb work steve

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    Official RnS Addict Ratty's Avatar
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    Re: Making a not so ordinary panel

    Facinating , and beautiful work too , looking forward to more !

    Does the panel flatten out naturally as you work the edge of the 'bulge' (I'm guessing by stretching the metal out again) or does it need extra work on its surface elsewhere ?
    I joined a nudest colony the other week . The first few days were the hardest ...


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    Full Time Metal Junkie ProMetalShop's Avatar
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    Re: Making a not so ordinary panel

    Hi Ratty
    That's a great question , and it tells me you have a great understanding for moving metal.
    First thanks guys for the kind words.....

    Ratty it had a good bit of distortion , but as I corrected the out edge of my stretch I kept it clamped to my work bench and with a nicely rounded chaser ( dressed chisel ) it really help relieve the stressed areas . Taking the shape gradually helps to keep the stress down but still needs to be convinced to lay flat... )
    Thanks Steve
    Shaping Metal Is Often Easier Than Shaping Minds

    http://chevylegends.com/forum/index.php

  9. #7
    Official RnS Addict Ratty's Avatar
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    Re: Making a not so ordinary panel

    Haha , I wouldn't go that far ! Unfortunately a severe lack of workshop time due to work commitments keeps my interest more theoretical than practical at the moment , but every day is a school day in my book and maybe one day work will allow me to take a half-arsed stab at bashing some tin around

    To be honest I was expecting a shape like you've created there to have been formed over a 'buck' as it were rather than formed pretty much by eye . I read a very interesting article a few years ago about removing pin-prick dents in panelwork using heat to reverse the stress which caused the damage in the first place and was mighty impressed , thats what turned me on to the elasticity of metal , a material I'd always assumed to be pretty rigid , so I kinda guessed at what you were doing by working the edge .

    Can't believe I've missed your posts before , just done a search of you previous ones and I reckon I've got a good evening's reading ahead of me ! One of the things I love most about this hobby of ours is that people such as yourself find the time to share your knowledge and time with others , I'm sure I don't just speak for myself when I say thank you for that
    I joined a nudest colony the other week . The first few days were the hardest ...


  10. #8
    Full Time Metal Junkie ProMetalShop's Avatar
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    Re: Making a not so ordinary panel

    A wooden buck would have been a great way to get the same results but I was low on forest material. and I was not sure it was the shape I was looking for so I drew out what I felt I wanted to see and kept going until my shape was deep enough to fit under the bonnet latch brace. I do quite a bit off hammer form but on a spur of the moment thought I beat it into a bag and hope for the best
    Thanks Steve
    Shaping Metal Is Often Easier Than Shaping Minds

    http://chevylegends.com/forum/index.php

  11. #9
    Official RnS Addict Ratty's Avatar
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    Re: Making a not so ordinary panel

    See , if I'd done that it would've ended up looking like it had caught fire and someone had tried to put it out with a shovel ...
    I joined a nudest colony the other week . The first few days were the hardest ...


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    Re: Making a not so ordinary panel

    Lovin your stuff. Great use for a baseball bat

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