Custom Sheet Metal at home

Any one here have any experience with custom sheet metal work at home? If so, any advice? pointers? etc

I'm thinking about lightening my challange project by making custom thin sheet metal bumpers (76 Olds Cutlass = heavy bumpers)

+1 on the cardboard template.

Most of the things I make have a right angle bend - for that, I clamp the sheet metal between two pieces of angle iron on my bench. Then I heat the edge with a propane torch and hammer out the bend. It works reasonably well - the propane torch does actually make a difference.

In the absence of 'real' sheet metal working tools you'll need some angle iron, a good bench, a good vise, plenty of clamps, wood, hammers and other various hand tools.

You can bend over pipe for rounded corners.

It helps to tack weld the metal to your form in some instances.

There was a link years ago on GRM about some guys south of the border restoring a VW bus with primitive tools, and doing a better job, apparently, than 99% of autobody or sheet metal workers worldwide

-James

Here you go. See you in about a year.

http://www.metalmeet.com/forum/index.php

The above site is what led me to believe I could do this project. http://www.cardomain.com/ride/2203663

I curse them on a weekly basis for planting such a seed!

I have made various panels over the years. In addition to the above sites I like http://www.allshops.org/ Try their forums section. They also have tutorials.

NOHOME wrote: Here you go. See you in about a year. http://www.metalmeet.com/forum/index.php The above site is what led me to believe I could do this project. http://www.cardomain.com/ride/2203663 I curse them on a weekly basis for planting such a seed!

Thanks a lot! I still haven't recovered from my first visit to the Garagejournal.

I have bent long straight sections by using a pair of 2x4's as a brake. Draw your line, put a 2x4 top and bottom and clamp tightly with welders' clamps or similar. Then use a deadblow hammer up and down the bend until it's where you want it. That's how I formed the rear lip on the Abomination's spoiler.

Check Harbor Freight as well. Sometimes, the $50 you spend there can save a lot of headaches. Sure, their stuff isn't pro quality, but your no pro.

jamscal wrote: There was a link years ago on GRM about some guys south of the border restoring a VW bus with primitive tools, and doing a better job, apparently, than 99% of autobody or sheet metal workers worldwide -James

It was Thailand, and it took a little digging, but here's the link:

http://www.vwrides.com/viewtopic.php?t=43&postdays=0&postorder=asc&start=0&sid=085f86cd93562e0317b1eefe64786a14

Get a cold drink, block out some time and prepare to feel your jaw drop.

If you want to see some GRM metal working, check out how the guys makecooking pots and long guns in the middle east.

Jaw is perma-dropped. That bus must have 60,000 hours in the metal work alone!!! Did they seriously make bead rolls with a chisel and hammer?! I'm feeling lazy all of the sudden.

We're not worthy.................

TIGMOTORSPORTS wrote: I'm thinking about lightening my challange project by making custom thin sheet metal bumpers (76 Olds Cutlass = heavy bumpers)

Could you remove the bumpers and use them as a buck for a fiberglass duplicate? Fiberglass is just easier to schmooze around than metal.

Dan

No fair 914 stole my answer.