All MetalShaping

Go Back   All MetalShaping > Metal Shaping Projects > Beginner Projects
  Today's Posts Posts for Last 7 Days Posts for Last 14 Days  

Reply
 
Thread Tools Search this Thread Display Modes
  #1  
Old 05-27-2013, 11:57 PM
Rick Evans's Avatar
Rick Evans Rick Evans is offline
MetalShaper of the Month August 2013
 
Join Date: Jul 2012
Location: Phoenix AZ
Posts: 152
Default How to make a '32 Grille

If you want to see how a pro makes a aluminum grille from scratch check out this Street Rodder article by Ron Covell. If you wanna see a metalshaping newbie atempt to do the same thing... read on.

This is the first bit of metal I've run through the english wheel that I recently made. I have only previously made a gas tank for a motorcycle and I've never welded aluminum before.


Following Ron's example I made a hammerform. I cut out the outside grille shape out of MDF (medium density fiberboard). To make sure the left and right sides match, I tack welded two sections of bar together and bent them at the same time using some heat from a torch and a bench vice.




Then I separated the bars, trimmed and tack welded them back together to form the inner bar structure.




The inner bar structure was then tack welded to steel stanchions. Nuts were welded inside the stanchions and then bolted to the MDF form. Building a hammerform takes a bit of time up front but will save you time in the end.




Brown paper was used to create the general shape.




Template was then transfered to aluminum. Be sure to leave enough overlap to allow for shrinkage.




I trimmed mine out with a Harbor freight metal shears. These shears actually work pretty good and are only about $30.




A baseball mallet and stump were used to create shape.




The aluminum shapes really fast. I got lost in the moment and forgot to get more pictures of the shaping process.




Bottom piece after wheeling.




Side pieces didn't require alot of shape. A rubber upper wheel was used to add some curvature.




Side and top pieces mocked onto the hammerform.




Don't use a sharpie marker for this, the fitment needs to be precise as possible to allow for a tight gap. A scribe was used to mark the cut line.




Trim to the scribe line. (If you would like to increase the difficulty use wrong handed tin snips like I did.)




To learn how to weld I rented a gas welding video from TM Technologies for $9. If you have the extra cash get a pair of the TM2000 welding glasses too.

Aluminum is tough to figure out. Make sure to remove the oxidation layer with a wire brush and use plenty of flux. This weld is definitely ugly, but easily fixed.




Evidence of the ugly weld is gone after a little metal finishing.




The inner flange was tipped on a bead roller.




Then mounted to the hammer form with screws.




To keep from marking the aluminum, a plastic teardrop mallet was used to pound over the inner bar.




The aluminum was annealed at the corners due to the tight radius.




The inner flange and outer shell were scribed and trimmed for a tight fit.




Then welded together...




and metal finished.
__________________
Rick
Reply With Quote
  #2  
Old 05-28-2013, 12:17 AM
Rick Evans's Avatar
Rick Evans Rick Evans is offline
MetalShaper of the Month August 2013
 
Join Date: Jul 2012
Location: Phoenix AZ
Posts: 152
Default


A close up of welded and metal finished welds.




After mocking up the grille I decided that it was 3 inches to tall. Someone's about to get some more welding seat time...




A bullseye pick is used to raise low spots after welding.




A vixen file is used to remove the high spots.




Low spots are again raised with the bullseye pick.




and vixen filed again. This would be close enough for paint with a layer of high build primer.




The finished grille.





and a couple of shots of it in the car

























__________________
Rick
Reply With Quote
  #3  
Old 05-28-2013, 12:37 AM
Ben's Avatar
Ben Ben is offline
MetalShaper of the Month Dec 2010, Sept 2015, Jan 2016
 
Join Date: May 2010
Location: The Netherlands
Posts: 644
Default

Hi Rick,

looks great thanks for posting this.

Ben
__________________
Ben
www.mechammer.com
Reply With Quote
  #4  
Old 05-28-2013, 01:06 AM
gerry miller's Avatar
gerry miller gerry miller is offline
Member
 
Join Date: Jun 2012
Location: RockyFord,Colorado
Posts: 291
Default

Nice pics and Nice freekin Job . Really enjoyed your fine explanation.
Gerry
__________________
Gerry Miller
Reply With Quote
  #5  
Old 05-28-2013, 05:24 AM
Peter Tommasini Peter Tommasini is offline
MetalShaper of the Month May 2013, Dec 2013
 
Join Date: Apr 2011
Location: Melbourne,Victoria, Australia
Posts: 7,750
Default

HI Rick the grille looks great
Peter
__________________
P.Tommasini

Metalshaping tools and dvds
www.handbuilt.net.au

Metalshaping clip on youtube
http://www.youtube.com/watch?v=WEAh91hodPg

Making Monaro Quarter panel:
http://www.youtube.com/watch?v=KIpOhz0uGRM
Reply With Quote
  #6  
Old 05-28-2013, 06:37 AM
Garagemsantos Garagemsantos is offline
Member
 
Join Date: Sep 2011
Location: Denmark
Posts: 24
Default

Very nice work. And thanks a lot on posting all the process pictures.
__________________
Best regards.
Santos
Reply With Quote
  #7  
Old 05-28-2013, 06:44 AM
Kerry Pinkerton's Avatar
Kerry Pinkerton Kerry Pinkerton is offline
Administrator
 
Join Date: May 2009
Location: Near Huntsville, Alabama. Just south of the Tennessee line off I65
Posts: 8,321
Default

GREAT post Rick! And the metal shaping is great too!
__________________
Kerry Pinkerton
Reply With Quote
  #8  
Old 05-28-2013, 08:55 AM
Mike Hendrix Mike Hendrix is offline
Member
 
Join Date: Nov 2011
Location: Williamson, Ga.
Posts: 104
Default

Nice work Rick, I like what you used it on too. A lot of good work if you look at it close.
__________________
Mike
Reply With Quote
  #9  
Old 05-28-2013, 09:12 AM
HEATNBEAT's Avatar
HEATNBEAT HEATNBEAT is offline
Member
 
Join Date: May 2009
Location: Madera,Ca. Home of Yosemite
Posts: 6,058
Default

Very nice Rick! and your first time gas welding aluminum even better!
__________________
Rick Scott
The second mouse gets the cheese!
Reply With Quote
  #10  
Old 05-28-2013, 10:09 AM
keith keith is offline
MetalShaper of the Month November 2021
 
Join Date: Sep 2009
Location: Sedalia, Mo.
Posts: 349
Default

That looks great Rick. Thanks for posting.
__________________
Keith Daleen
Sedalia,Mo.
Reply With Quote
Reply

Thread Tools Search this Thread
Search this Thread:

Advanced Search
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump

All times are GMT -5. The time now is 08:08 AM.

Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2024, vBulletin Solutions Inc.