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Old 12-05-2017, 10:18 PM
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Fabricating hard lines

Hello all .
Im in the process of fabricating custom cab rear wall and corners .
I am unsure how to create hard internal angles in the steel sheet .
In the pics you can see the hip ive fabricated and am going to run a hard inward 90 degree curved down (can see the bend ive put in it so far in the picture but its got to match the old original hard line in the black painted section) .
I seen on youtube a guy use a bead roller with a special wheel roll an internal corner but I dont have the wheel attachment though I do have a bead roller , english wheel and pneumatic planishing hammer .
Any tips would be greatly appreciated .
Thanks
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Old 12-05-2017, 11:22 PM
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Pics to help explain
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Old 12-06-2017, 07:24 AM
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I think the easiest way would be to make the curve and end it where the roof starts then bring the roof down in a separate piece, two ez pieces instead of one hard to make piece. That compound curve will be hard enough to wrap around from the side to the back without that sharp angle to deal with.
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Old 12-06-2017, 10:41 AM
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Do you have the old Panels? If you do, one of the best Metal Shapers around (Wray Schelin) also had a problem replicating the proper surface area (bulge/curvature) of Panels such as yours-

Wray came up with the idea of using Transfer Tape (used for signs, crafts and such) and to criss-cross the tape on the original panel to obtain the proper surface area-then he would use this Tape on the new panel to be certain that it "bulged" the proper amount (a pattern per se)-

Since you already have planishing hammer, I would continue on and finish the panel you started(you'll learn something at least with it), using the tape pattern to get it correct-

As for the Body line, I believe the Tool you are referring to is called a Tipping Wheel-the best place to buy one those is Hoosier Profiles https://www.hoosierprofiles.com/bead-dies-.html

They also offer radius Dies which may be needed to form that upper edge, or, I would use a Shrinker to obtain that profile (this could be also done with "Tuck" Shrinking but it takes a bunch of time)-if you've done this type of work before you know that you'll throw away a few (or more) Panels, as this is one of the harder pieces to make, don't get discouraged-

As for your rear Panel, no Car/Truck back then had flat Panels, and your rear Panel is no different-one of the strategies is to make a grid on a Panel and then (using your Planishing Hammer) make the same amount of hits in each square to increase surface area (curvature)-it would be easier with an English wheel however-this is tedious work-or you could do an Ian Roussell and find something in the Junkyard that has the proper curvature and weld it in-

There are lots of different ways to make these Panels-
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Old 12-06-2017, 12:27 PM
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I think I would want to patch the roof part and leave it a little long, mate the cab corner at the hard line and weld there on the outside then grind both sides. Trying to make the patch with that line in it bumps the difficulty way up. If you wanted to make the roof and cab corner pieces seperately and weld that seam with the rest of the seams just tacked... then cut the tacks and finish the patch nice off the truck and install it as one... you could do that. Go with whatever sounds most do-able.
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Old 12-07-2017, 07:05 AM
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Nice project. very cool. how about some more pics.
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Old 12-07-2017, 04:49 PM
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Few updated pics .
Ive decided to make the hard line with two pieces as described earlier in the thread. Bit mor shaping of the hip are and I should end up with something workable .
Ive made the back cab wall reasonably straight instead of a rounded bulge type with a biew to fitting a custom fuel tank fitted in against it .
You can see in the pics how it was when I got the ute . It wass pretty carved up in the styleside body so I removed it and have a tow truck jib Im contemplating fitting as a rat rod .
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Old 12-08-2017, 11:37 PM
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you would have needed the embossing dies to do that. It would have been done last after shaping and would have been as simple as running it thru the roller given the metal shaping was good, which it looks to be. The problem with welding in that corner is that when it's all said and done is it gonna have that crisp corner? If you grind and file it smooth to get that smooth look that's more work than making it in one piece. Just my opinion.
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Old 12-09-2017, 11:45 AM
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needs more rubber out back
very cool project, what is the original vehicle?
i'll assume one of those utes you guys have downunder
do you have a pic of the original vehicle?

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Old 12-09-2017, 03:43 PM
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Its a 1950 holden FJ .
The green pic is an original car and the black I how mine was when I bought it .
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