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  #1  
Old 10-28-2017, 07:58 AM
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Steve Hamilton Steve Hamilton is offline
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Default Corvette metalshaping

Hi all
A customer brought me this part for his 1963 split window corvette. No repro of this is available.
A former owner had stored the car in a barn with the window open about 40 years ago. Raccoons moved in and used the roof as an outhouse. The drip rail and structure over the door rusted away. Hamilton Classics to the rescue, I thought it would require at least 35 to 40 hours labor.

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Old 10-28-2017, 08:39 AM
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With any big project, take it one step at a time. Break it down into manageable size sections. With the old part for information made patterns and cut out the blank. Started by making the oval hole with flange. Scribed the oval using the original part, then marked for the cutout 1/4 inch smaller for the material needed to create the flange. Tipped the flange with pliers, vise grips, and hammer / dolly.

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Old 10-28-2017, 09:50 AM
Dave K. Dave K. is offline
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Steve, as always: AWESOME! It is great that you show us how things are made!!
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Old 10-28-2017, 11:49 AM
RockHillWill RockHillWill is offline
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Cool stuff there, Steve. Keep the pictures coming.
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Old 10-28-2017, 03:34 PM
Mike Motage Mike Motage is offline
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Pretty cool, Steve! I would like to see all the different steps as well.

Thanks again
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Old 10-28-2017, 09:51 PM
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Thanks guys
Mike you must be a mind reader, that is what I planned to do!
I did not take step by step pics when I was making the oval hole so I went out tonight and made a quick example!


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Old 10-28-2017, 10:35 PM
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Started the flange tip with the vise grips because I needed a narrow tip tool to do the 2 inch dia. Next linear stretch the flange. The most stretch needs to be close to the edge so tip the hammer so that the edge gets hit harder. I put the panel tight against the sharp edge of the table. Keep the flange tight to the table while rotating the panel and evenly spacing the hammer blows.

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Select the tool that best suites th task, small contact area to thin and stretch, large contact area to smooth and blend. I chose a dolly with a very sharp edge to help set the corner. The round bar can also be used like a slapped / flipper.

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The the radius from panel to flange can be made sharper by holding it against a solid table an tap down on the edge of the flange like below.

More later
Steve

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Old 10-29-2017, 03:34 AM
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Excellent. Thanks for showing the step by step.
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Old 10-29-2017, 06:10 AM
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Nice work.thanks for showing how you did it
cheers paul
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Old 10-29-2017, 07:00 AM
Rex_A_Lott Rex_A_Lott is offline
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Nice write-up, Thanks Steve!
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