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Old 02-11-2016, 11:32 PM
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Steve Hamilton Steve Hamilton is offline
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Default Small complex panels

This tutorial is designed to explain a process of making small complex parts that need to fit accurately around chassis & engine components.
A buck was not a practical option so i did a little free style, shape a little then test fit, shape some more. I did cut out some tag board and tape it together to get a visual and to cut out blanks.


IMG_0544.jpg

IMG_0548.jpg

tight clearance between the frame and turbos required some creative work to get a nice looking part that blends with the rest of the project

IMG_0568.jpg

simple bends at the bottom, but a wave and a radius at the top. the flange will be welded on to the side panel for the engine compartment.

IMG_0570.jpg

Now that looks about right, now i need to make a mirror copy that is the same shape.

IMG_0529.jpg

IMG_0541.jpg

tight..... just room for my first knuckle
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Old 02-11-2016, 11:54 PM
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The flexible shape pattern was used to get panel size and placement of stretching. the pattern was cut accurately so it could be used to layout the flange and the cut line for the weld.

IMG_0575.jpg

IMG_0577.jpg

pattern shows stretch, I transfered that to the blank

IMG_0578.jpg

IMG_0579.jpg

IMG_0580.jpg

linear stretch dies were used in the power hammer, could have been done by blocking, and wheeling or with a planishing hammer.

IMG_0581.jpg

IMG_0582.jpg

IMG_0583.jpg
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Old 02-12-2016, 02:30 AM
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Steve, nice job on a very complex panel. Thanks for showing your work.
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Old 02-12-2016, 03:14 AM
metalman sweden metalman sweden is offline
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Nice Steve!
Thanks for taking your time to post!
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Old 02-12-2016, 04:48 AM
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Thanks for showing how you went about it.
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Old 02-12-2016, 09:29 AM
crystallographic crystallographic is offline
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Lovely work with sweet contours.
Makes me smile to see it all coming together with such a nice flow.
(nice patina on your work surface )
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Old 02-12-2016, 12:44 PM
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thanks guys.

a couple more pictures of the tight clearance, and frame trimming required to achieve the final clearance. At the beginning there was only a 1/4 " space. Lots of head scratching, customer wants the turbos and engine to be the focal point, so not many choices of where to put the turbos.

IMG_0542.jpg

IMG_0557.jpg
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Old 02-12-2016, 01:11 PM
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Default Tipping the flange

The flexible shape pattern works better on a panel with more shape, so I roughed in the stretch areas and was careful not to overstretch, my guess was that it needed more but I could add more later. I chose a flange width of an inch because it needs to be welded to another panel and I wanted some room to finish off the weld zone later. The tall flange made shrinking the front corner more difficult, but still possible.



rolling a crease into the panel with my powered pexto the lower is a firm nylon.

IMG_0584.jpg

Attachment 36233

IMG_0587.jpg

IMG_0588.jpg

IMG_0589.jpg

IMG_0590.jpg

IMG_0592.jpg

more shrinking & tipping to get 90*

IMG_0596.jpg

IMG_0597.jpg

match the backup tool to the curve and the sharpness of the crease.
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Last edited by Steve Hamilton; 02-12-2016 at 01:31 PM.
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