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Old 01-30-2005, 02:11 PM
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Lightbulb roll pan delimma

im wanting to make my own roll pan for my 86 chevry truck. heres the problem. im illiterate at sheet metal working, and have few tools to do it with. its a basic design, but it has a slight curve in it. what type of metal should i use, how can i get the contours just right, and how thick should it be? im planning to put some 4 inch round tail/turn lights in it. any ideas as to what to do with my liscence plate? i want something unique and hand made by me. thanks in advance!

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Old 01-30-2005, 04:41 PM
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20 gage cold rolled steel. And if you have a Heating and Air CConditioning company around, hook up with them and see if they have a set of rollers they can run it thru for you. They would probably charge a couple of bucks to do it. And look in the Yellow Pages for sheet metal fabricators if there is no HVAC around. To get the shape you need, take some poster board and trace along the fender where it will go to get the profile that you want, then carefully measure the length you need.

Kevin
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Old 01-30-2005, 04:59 PM
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thanks for your help, another thing just came to mind... would it be best to use a bumper bracket and install it, or should i just weld it in place.
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Old 01-30-2005, 06:04 PM
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Weld. Or have flanges to the sides and top and bolt it.
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Old 01-30-2005, 06:17 PM
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i already have some sheetmetal... its thin yet very hard. it came off of a old silo at an asphalt plant... how do i know what gage it is and is it ok to use?
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Old 01-30-2005, 08:16 PM
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Measure it with a vernier or micrometer if you have one. 18ga mild steel is around .050". 16ga is around 1/16" as a reference if you only have a measuring tape. Another guestimate way of telling.....grab a corner of unformed sheetmetal with your fingers while you push up on the unsecured corner with your thumb...if it bends with some resistance its likely around 20ga or so. If it will not beng at all its likely 16ga or heavier. If it bends really easy its probably in the 24ga range. A lot of sheet metal flashings on metal buildings runs around 26-24ga. Hope this helps....its the best I could describe.....
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Old 01-30-2005, 08:20 PM
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thanks, this stuff was given to me, and its 1/4 inch thick, but it will bend, is this too thick to use?
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Old 01-30-2005, 10:12 PM
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About your liscence plate, have it recessed into the roll pan would look good. But another neat they showed on "trucks tv" is a liscence plate "holder" where you bolt your liscence plate on, and it has a little electric engine. You run a switch to your cab and when you activate it the plate electrically flips up down below the frame and it loooks like you have no liscence. Flip the switch again and it pops back down right under the roll-pan.




Mike
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Old 01-31-2005, 06:14 AM
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curves

One of the simplest things that can be done is to just clamp the metal down to a board or your bench using a piece of pipe and then bending the metal around the pipe until you get the curve you want..

This can be done by hand if you are careful..Be on the lookout for metal from old vans and pickups for metal sources..lot of those have good size pieces of metal that can be used..

OMT
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Old 01-31-2005, 09:51 AM
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Quote:
thanks, this stuff was given to me, and its 1/4 inch thick, but it will bend, is this too thick to use?
It's not 1/4 steel if you can bend it by hand. You want something around 20 gage or .035-.040 thick. Not sure what the conversion factor is right now from gage to thousandths.
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Old 01-31-2005, 01:00 PM
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Re: curves

Quote:
Originally posted by OneMoreTime
One of the simplest things that can be done is to just clamp the metal down to a board or your bench using a piece of pipe and then bending the metal around the pipe until you get the curve you want..

This can be done by hand if you are careful..Be on the lookout for metal from old vans and pickups for metal sources..lot of those have good size pieces of metal that can be used..

OMT
thanks, ill try that... oh, hey kevin, i just went ahead and bought a sheet of 20 gage cold rolled steel from our local steel shop. that way i dont have to worry about the other metal. thanks alot you guys. ill let you know how it comes out soon.
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Old 01-31-2005, 02:09 PM
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Metal forming

WHATEVER YOU DO, DO NOT BE AFRAID TO MESS UP!! That is how we learn this stuff..A nice car body can be built using some hammers a sandbag, a stump, some simple hammer forms and an ordinary gas torch.

Every now and again I get stranded and have to have the store bought tool but for the most part if I can make something to do the job I will do that..

OMT
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Old 01-31-2005, 03:33 PM
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Good luck. Remember to go slowly. Make a template of some cardboard if possible. I'd love to see pics when its done. I'm working on an '87 shorty, and want to make one too. I'm planning on making the licence plate fold down for a trailer hitch.
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Old 02-01-2005, 09:08 AM
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Cold Rolled Sheetmetal Guages to decimal eqivilent

4 .2242
6 .1943
8 .1644
10 .1345
12 .1046
14 .0747
16 .0598
18 .0478
19 .0418 (Most popular car guage)
20 .0359
22 .0299
24 .0239
26 .0179
28 .0149


Use a pipe or a telephone pole to shape the roll pan. Look in my Project Journal for the Gene Winfield trip. There is a Pipe Horse, showing construction.Simple to make.
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