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Old 09-27-2010, 07:50 PM
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Metal Shaping

Info for a rear fender

Bondo buck to be used as a hammer form for lips and flanges. It will also be used to put the fender into arrangement.





Flexible shape pattern, to record shape.





Fit metal to pattern.





Gas welded with Henrob and re-stretched the haz on planishing hammer







Still needs cleaned up but here is the other side cleaned up


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Old 09-27-2010, 08:11 PM
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DAMN!!! That is fing nice
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Old 09-27-2010, 08:16 PM
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Not bad for a hair lip!
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Old 09-27-2010, 09:29 PM
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Thanks I think

Any interest in metal shaping here, or I am just passing through
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Old 09-27-2010, 10:31 PM
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We do try and encourage metal work here..Good luck as I hope you have better luck in that area than I do..

Sam
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Old 09-27-2010, 11:03 PM
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Very cool stuff, I never get tired of seeing it, thanks!

Brian
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Old 09-28-2010, 12:17 AM
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Originally Posted by MARTINSR
Very cool stuff, I never get tired of seeing it, thanks!

Brian
X2, very nice, you made it look a lot easier than it really is tho!
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Old 09-28-2010, 07:18 AM
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Quote:
Originally Posted by jhnarial
...Any interest in metal shaping here, or I am just passing through
Yes there is interest. And the more detail the better. For example, I'm curious about the process you use to begin forming up the skeleton of metal rod you use as a base for your sheet metal...how you match this up to your original or your custom design.

As always...the more pics you can provide the better.

BTW, very nice work.
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Old 09-28-2010, 07:31 AM
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now thats just plain cool. nice work.
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Old 09-28-2010, 09:58 AM
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plenty of interest! I would like to see some pics of you shaping the individual pieces before you weld them up.
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Old 09-28-2010, 03:31 PM
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Quote:
Originally Posted by jhnarial
Thanks I think

Any interest in metal shaping here, or I am just passing through
Interest ? ohh yes very much so, now the skills to do that work I haven't mastered yet I could use a set of fenders similar to that, I for one would love to see more on the steps to make parts like that.

Oh and welcome to the site there are plenty of builders on here

Brian kc0kfg
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Old 09-28-2010, 04:15 PM
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Ok step by step.

I won't be able to do it all in one night but let's see what we can do.

I'm a rookie metal shaper at best. I shaped the drivers side fender 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.





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 removed the wire form.



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



Then apply the bondo and let it set up.




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



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.
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Old 09-29-2010, 08:03 AM
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Quick question. Is the purpose of the bondo to mimic the EXACT shape of the inside of the original fender?
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Old 09-29-2010, 04:08 PM
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It is a exact copy of the fender. It's purpose is to give you something to clamp the panels together, clamping the fender to the buck will put the panels into it's proper arrangement for scribing cut lines and also welding.

You could shape the fender to the buck but I take a different approach.

The buck is not necessary for a one off panel, it's more for mass production. I just built it so I could use it for a hammer form for the lips and flanges. Now that I have the shape I can clamp the fender to the buck hammer over the lips and it will be exactly like the stock fender.
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Old 09-29-2010, 04:26 PM
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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.



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.



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.

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