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Old 05-23-2009, 06:51 PM
Kerry Pinkerton's Avatar
Kerry Pinkerton Kerry Pinkerton is offline
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Join Date: May 2009
Location: Near Huntsville, Alabama. Just south of the Tennessee line off I65
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I've realized that in my haste to get to shaping the body, I've probably cost myself time by not taking the time to build a wooden station buck up front...

When I did the second front fender, I really struggled with getting the same arrangement as the first fender. The rears are even more complex and after a couple false starts doing without, I decided to build a buck. The challenge is that the first fender is already built and I have to build a mirror image buck. Here is how I'm going to do it...hopefully it will work.

The lengthwise part was first. I have a 6' flexible contour guage and I carefully laid it guage on the completed rear fender front to back and transferred the line to some 7/16 OSB. This was then mounted to some feet, squared so it sits vertical and screwed to the table. A few holes were drilled in the fender and it was screwed into the buck to stabilize it while I made the stations.

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Because of the extreme shape of the fender, I had to make this in two parts that I can assemble once the fender is in place on the front part.

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Using some small contour guages, I made the crosswise stations. Each one is screwed into a 2x2 and that is screwed to the lengthwise portion. It is very stable but I'm not going to be using it for a hammerform. I didn't get too carried away with spacing them evenly but rather put them where I felt I needed the information. The other side is staggered for reasons that hopefully will make sense in part II of this thread.

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Hopefully tomorrow, I'll get to reverse these and convert this from the right side to a mirror image for the left. It is not as simple as it might seem at first thought. I've been noodling over how to do this for a couple weeks now. I have a plan...we'll see if it works.

Still only have 1.63 hands but cabin fever drove me out in the shop and I managed to reverse the buck.

The hard part was making sure that the ribs were in exactly the right place and orientation on the other side. I came up with this idea. I marked both sides and the bottom of the OSB ribs and simply drilled a 1/8" hold ON the line and pressed a finish nail through the hole...

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so it came out the other side...

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and that gave me a perfect locator for the reversed rib.

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Here is what I started with.

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And here it is reversed.

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Now I can make sure all the sub panels are in correct arrangement as I tack them together. This was a pain to build but in the long run it will be worth it and I'm wishing I had done the same thing on the front fenders... Ain't hindsight grand!

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Quote:
Originally Posted by Overkill
Just wanted to mention this, as I watched the DVD last weekend. Ron Covell has a new DVD out on how to build a fender - using a 36 Ford rear fender as the demo piece. What I found interesting was his methodical method of building a buck. There are areas of the buck used for hammer forming, other areas just to keep you on the right track. John

Yeah I understand....In retrospect, I should have built the chassis, then built a wooden buck that worked with the chassis...then when I rebuilt the chassis, I'd have to rebuild the buck...then when I went to chassis #3...well you get the idea... Nothing like having a plan right?

If I ever finish the roadster, and live long enough, I'm going to build a coupe version. I'll be able to make bondo bucks from the existing fenders and body panels. That will solve my buck problems on car #2
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