Now onto the other side, I expect it will need the same treatment
Due to popular demand I have detailed the steps needed to create the panels, hope I have made it easy to follow
This is what I start with, a peice 1mm Mild steel Zintec sheet.
Then measure the panel
and transfer the sizes to the new steel
and we get this, bend lines also transfered and marked so I fold it up right later
Then cut it out, I generally just use a good quality pair of Gilbow shears for most of my cutting out , although I am hopeing for a nice throatless bench shear for Christmas
I use 2 types of bender, the first is one I bought from Machine Mart or somewhere like that, it is ok, does not do tight bends, but they are even and fine for these type of repair panels
The second is home made, I made this about 20 years ago, and I have used it on every job I have ever done since then, it is a simple design, that basically just clamps 2 peices of angle together, to then allow you to tap it over with a hammer. It also doubles as a small work bench and anvil type thingy.
This has been a godsend over the years, and as it is portable it goes to every job with me
I moved the loose angle in this shot so that you can see how it works
As the bends are straight forward it was into the MM folder, using the fold lines earlier marked to line it up
and that gave this
Then spin it round and put it in again, you have to think through the sequence of bends to ensure that you can always access the bend you need to create
and you get this, up 45 degrees
Next bends would not fit into the MM bender so the HM one was used.
And then folded over, with large peices like this you can normally just push it over with your hands.
and then rearrange as needed
This was a bit tighter at the end so needed dressing over with the hammer.
That gives us this
Then back into the bender
Then up 90 degrees
Then into the other bender
and dress over
We get this, note the puckered edge, this is to be expected as there is too much metal, I could have cut it and welded it.
But instead just prefer to dress it over and force the metal into itself
this takes several minutes or careful hammering as you don't want to stretch the metal.
But you end up with this
Then the ends need folding, due to the configuration of bends I cannot do these in either of the benders, so these have to be manually dressed up. Going back to my earlier point about thinking of the sequence, if I had done these first I would have really been stuck.
So I use a steel block that I have
And dress the flange up against it
You get this
So that is the straight forward bits out of the way, I then need to detail the other end, a small snip is needed, here
And then start to dress upto the block
But only 45 degrees
Then turn it over and dress it up again, smaller dolly needed this time, to get in, the bigger one is much better for dressing against as it is heavier.
Almost there now
Just needs some tidying up
And there you have it, should be okay, and might need a little tweaking during fitting
Once you break the panel down into individual bends, it is quite easy to create some fairly complex parts with just basic tools
Great work again! Thanks for that. My metal folder is slightly different to yours. I think I need to manufacture one like yours as it looks to have some advantages. Will try to use these techniques next time I make some panels.
I think we all knew that was coming, so out with the twist knot brush just to check
Yep well and truly needs attention
But need to finish of my next bit first, this is it marked up and cut out, cut the hole out using my Jigsaw
Then start the folds
As you can see the folder has no bottom, so when folding tall sections you can just tip it on its side and feed parts through
Then over and back in
Dressed down to this
Then fold the other end
Ends up now
Thats the bulk of it
Just the edge around the hole, so start with the mole grips
And up we go, a little at a time
First time around
Just needs a little dressing to finish, on this type of bend you need to stretch the metal, so I use the cross pein end of the hammer against a block, as it squares things up, it also squashes the metal, thus stretching it too
A bit more definition needed
A different block for the tight spots
And there you are, just a run over with the file is all that is needed now
Oops almost forgot the bulge needed to clear the seam and let the water out
I am going to need this
That gets us the rough shape
So then I need something round and hard, this will do
Then dress it as needed
And check for fit
Looking good, another one down
So then back to the car to see what we can do with the bulk head part, it was actually worse than the other side and all needed to come out
What you could not see was the back, which was inside the car, it was rotten right through.
This looks like it might be tricky to make
Will have to leave it there for the moment, more soon
Yep, just echo what everyone else has said. Fantastic skills, can't wait to get back in the garage and start making stuff!! Will the car go back to standard other than the colours or are there other plans afoot? Thanks for sharing too