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Old 05-22-2009, 10:18 AM
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aluminum quarters?

setting the scene! i got a 72 buick skylark 350 hoping to be a 455 soon. she is a rusted hulk but i love her, thought about selling but i can't bring myself to do it. aside from some great stuff and bondo i've no experience in body work. plus i'm broke so new quarters and fenders are out of the question, also don't know how to weld. a big part of it is the fun learning experience i'll get from it.

however i do have an english wheel and this idea of buying aluminum sheet, cutting it and shaping my own patch panels with or without the english wheel. then pop riveting them to the body. after that i'm gonna have my friends clear coat her or i'll do it myself.

i want to strip the paint. what is the cheapest best way of doing this?
i've heard i gotta stay away from a DA cause it'll warp the metal from the heat and believe me she's wavy enough.

when i'm cutting out the rusted body panels is it wise for me to use a cutting disc or should i look for a cheap torch or plasma cutter?

as for metal shaping i might just use a tree trunk and a rubber mallet. does anyone have any tips for shaping and cutting aluminum? it's not going to be full quarters and fenders it'll prob just be from the body line down. what i'm worried about is when i have to cut and bend for the wheel wells and the lip and the bottom?

any other advice? i may be leaving some stuff out but i'll add as i remember...

thanks in advance!
Adam

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Old 05-22-2009, 11:08 AM
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Go to www.metalmeet.com for advice on making panels..and you can cut with a cutting wheel in a disk grinder if you do not have a plasma..Ferrari's were built with a stump and a mallet so yes you can make your own panels..Also look up Randy Ferguson as that guy makes complete bodies from flat metal..

Yup you can do this but it is time consuming to do so ..that is why more do not do it..

As far as stripping the DA is fine for that and just use a spot blaster to get in the corners that are hard to get to..

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Old 05-22-2009, 04:57 PM
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an issue i've be hearing about is the galvanic corrosion problem with aluminum and the difference in the steel and aluminum causing problems. i plan to get everything lined up, drill the holes and then have the metal clear coated before reattaching everything. i also plan to use aluminum pop rivets. does anyone know if the clear coat will take care of the corrosion and differing metal issues? if not is there a cheap solution?

thanks in advance!
adam
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Old 05-22-2009, 04:58 PM
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hey thanks sam!

one question what is a spot blaster?
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