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WCRiot 11-08-2017 01:20 PM

Struggling with metal shrinker/stretcher
 
Guys
I am trying to build new corners for the rain water channel for the inside of the trunk. See the yellow arrows in an example picture
https://i.imgur.com/PL3ljdL.jpg
This is a C or U Channel, but I am starting with an L. I figure i can always weld the wall on and covert the L to a C/U.
As another example image, I am trying to achieve this:
https://i.imgur.com/ZPKTha6l.jpg


When i shrink i start to get pretty good movement. But with only shrink on this side I can only get so far. This picture is in process so I am able to get more radius to the bend than what is shown, but not much more.
https://i.imgur.com/E9lhXqol.jpg

So last night i tried switching to the streching die and hitting the other side. Thinking that i have done all the shrinking i can. Maybe stretching will help push the metal more to form that "C" shaped radius (from a top view). Is this the correct approach?
https://i.imgur.com/bmW9ifpl.jpg

The problem i see is that when i stretch, instead of the metal following the contour that formed from shrinking, the side of metal being stretched fans outwards. Create a fan or sea shell shape.

I used a different piece of sheetmetal to help illustrate what the stretching die does.
https://i.imgur.com/vzCWPJql.jpg

I will watch some youtube videos to try and learn how to achieve the shape i need, but wanted to get some advice from those on here.

gashammer 11-08-2017 01:35 PM

From my experience, that will happen. I generally finish the detailing on a sharp edged dolly to get the final shape.

Also, you have a lot of shrink going on. You may consider re-positioning the piece so that your die marks are not directly on top of one another. That could lead to cracking.

Kerry Pinkerton 11-08-2017 03:01 PM

Todd, I suspect your steel is getting work hardened. Lancaster machines are pretty hard on the metal. It will work great and then just quits like you are seeing. You might try some heat, bend the angle around the radius you want, and hammer down the tucks that pop up.

crystallographic 11-08-2017 03:15 PM

Quote:

Originally Posted by WCRiot (Post 141022)
Guys
I am trying to build new corners for the rain water channel for the inside of the trunk. See the yellow arrows in an example picture
https://i.imgur.com/PL3ljdL.jpg
This is a C or U Channel, but I am starting with an L. I figure i can always weld the wall on and covert the L to a C/U.
As another example image, I am trying to achieve this:
https://i.imgur.com/ZPKTha6l.jpg


When i shrink i start to get pretty good movement. But with only shrink on this side I can only get so far. This picture is in process so I am able to get more radius to the bend than what is shown, but not much more.
https://i.imgur.com/E9lhXqol.jpg

So last night i tried switching to the streching die and hitting the other side. Thinking that i have done all the shrinking i can. Maybe stretching will help push the metal more to form that "C" shaped radius (from a top view). Is this the correct approach?
https://i.imgur.com/bmW9ifpl.jpg

The problem i see is that when i stretch, instead of the metal following the contour that formed from shrinking, the side of metal being stretched fans outwards. Create a fan or sea shell shape.

I used a different piece of sheetmetal to help illustrate what the stretching die does.
https://i.imgur.com/vzCWPJql.jpg

I will watch some youtube videos to try and learn how to achieve the shape i need, but wanted to get some advice from those on here.

Hi WC,
Kerry and I are seeing that your shrink is going well until:
1) your metal gets hard
and
2) your metal gets thick.

You can also shrink when the metal is hot. Heat until it is past purple/blue and goes "black" then shrink 2 or 3 times, and then spray the jaws with alcohol to cool them (no rust).
You will find you can get more shrinking for longer if you do this, and the metal will not crack ..... at least not for me.

Jack 1957 11-08-2017 10:20 PM

1 Attachment(s)
One basic set of hardwood dies.

Attachment 44002

BTromblay 11-08-2017 11:53 PM

Hi,

In addition to the comments above, I have had good luck with making a pass thru the shrinker with the part at half depth of the die. Once you make a pass at half depth, tucks will form, go back full depth to flatten the tucks.

Bill

MP&C 11-09-2017 12:44 AM

When trying to shrink or stretch two parallel flanges (the C shape you referred to) I tip the flanges over at about 45* and then perform the shrink or stretch (as needed) until you have the desired radius, then use your flat body hammer to take the flanges over to 90*. This process was used the other day when making the radius corners in our console folds..:

https://www.youtube.com/watch?v=1NdR3c_S8nE


I did some repairs on a Fairlane trunk opening similar to what you are tacking now. Part of this repair had the two folded part that needed shrinking on two opposite flanges. Did the same thing here, bend to 45*, shrink, then fold to the needed 90...:

Quote:

Moving back to the trunk area, the more you look the more you don't want to.
The channel for the weatherstrip seems to have sealed water in as well as out....

http://i5.photobucket.com/albums/y16...Picture167.jpg

It took a few weeks and a few phone calls, but there are still some good junkyard pieces available. We got the corner pieces out of a yard in CO. The rear channel across the trunk opening also has scattered pin holes, so I though I'd give a shot to bending some new ones. First, need a template:

http://i5.photobucket.com/albums/y16...Picture168.jpg

http://i5.photobucket.com/albums/y16...Picture169.jpg

That looks close enough. My press brake dies are only about 18" long, so I'll need to do this in three pieces. The middle one got put in first.

http://i5.photobucket.com/albums/y16...Picture171.jpg

http://i5.photobucket.com/albums/y16...Picture174.jpg

Be sure to check the back side for weld penetration:

http://i5.photobucket.com/albums/y16...Picture178.jpg

The replacement corner was cleaned up, the spot welds were ground off of the adjacent pieces to release the corner with no damage. Looks quite a bit better than the old one.

http://i5.photobucket.com/albums/y16...Picture175.jpg

http://i5.photobucket.com/albums/y16...Picture179.jpg

http://i5.photobucket.com/albums/y16...Picture182.jpg

http://i5.photobucket.com/albums/y16...Picture183.jpg

http://i5.photobucket.com/albums/y16...Picture185.jpg

http://i5.photobucket.com/albums/y16...Picture187.jpg

http://i5.photobucket.com/albums/y16...Picture188.jpg

http://i5.photobucket.com/albums/y16...Picture190.jpg

Well, on to the next corner. The driver's side was in sad shape:

http://i5.photobucket.com/albums/y16...Picture193.jpg

But in looking at the replacement, although in better condition, it did have issues of it's own.

http://i5.photobucket.com/albums/y16...Picture194.jpg

Time to break out the trusty Lancasters and make some replacement parts.

http://i5.photobucket.com/albums/y16...Picture196.jpg

The replacement corner was left attached to the quarter panel section it came with while remaking the channel in an attempt to maintain the shape.

http://i5.photobucket.com/albums/y16...Picture197.jpg

Note the sharpie "reference lines" in the next picture, to keep the bend in the correct location.

http://i5.photobucket.com/albums/y16...Picture198.jpg

http://i5.photobucket.com/albums/y16...Picture199.jpg

http://i5.photobucket.com/albums/y16...Picture200.jpg

http://i5.photobucket.com/albums/y16...Picture201.jpg

http://i5.photobucket.com/albums/y16...Picture202.jpg

http://i5.photobucket.com/albums/y16...Picture203.jpg

....And a comparison of the "new" part to the old one. That should do the trick!

http://i5.photobucket.com/albums/y16...Picture205.jpg

Oldnek 11-09-2017 05:09 AM

Don't go to deep on the Shrinker or Stretcher. It will move more only working about 1/3rd of the flange.

Peter Tommasini 11-09-2017 09:29 AM

Todd
here a simpler way to do that panel
step 1 cut enough metal ( by paper pattern)
Step 2 draw with compass the curve needed + height of Chanel width and lip make sure to have enough panel steel on the other side of you chanel
step 3 bend all the width of the Chanel (height,width and lip) down on the wheel by (kicking the lower anvil up on one side) follow the inside line of your curve (this get's done bit by bit) stretch the side as you go ...you can control the curvature as you go ...in another words......not enough stretching ...the panel will be too round,
step 4 once the panel is at right angle turn the next part (been the width ) back at level plain with the rest of the panel by using a pair of pliers or... back on the wheel, stretch some more in order to keep the now downwards part ( the height) at right angle, once that is done use a piece of steel the width of the Chanel about one inch long or less and simply turn the last piece back up parallel with the height, cut what you need on the top (remember...??????) You had enough panel steel prior to scribe the curve) .....and you will have your Chanel and no welds or shrinking and stretching with machines involved
Peter

WCRiot 11-11-2017 05:27 PM

I tried annealing the original piece and that helped a little. I did a little tune up on the Shrinker dies. Here is a new attempt. Still using scrap metal:
https://i.imgur.com/SMwJTxUl.jpg
I got better curvature this time. It wasn't as difficult. I just wanted a few youtube videos by LAzze and that got me going.

I tried to figure out a way to make the U Channel then shrink but that was impossible. I then bent an "S" shape and shrunk accordingly. I struggled with that quite a bit. I Might be able to make that work with a combination of Shrinking and Stretching but gave up.

Here is what i am thinking of trying. Shrink one piece to the desired curvature. Then weld a second piece to complete the U Shape
https://i.imgur.com/Yx4O50Kl.jpg

End up with something like this:
https://i.imgur.com/b8FzEt0l.jpg

No one will really see this piece so if it doesn't look great, i can live with that. I think...

What do you guys think? I don't have a bead roller right now. I've been considering it, but don't have alot of need for it nor the garage space.

WCRiot 11-17-2017 02:12 PM

No one has a reply to my latest attempt?

crystallographic 11-17-2017 03:53 PM

Quote:

Originally Posted by WCRiot (Post 141314)
No one has a reply to my latest attempt?

Hi Todd,
I've been working on a pictorial answer for you ... I will post when it's done.

Kerry Pinkerton 11-17-2017 05:08 PM

Todd, with only a shrinker/stretcher available, doing two "L"s and welding together is about the only way I know of to end up with a "U" channel. That is how I will probably make the weatherstrip channel on my roadster. I could do a U channel on the Pmax or Eckold but getting the shape perfect in 3 dimensions would be a real exercise in frustration.

Peter Tommasini 11-17-2017 05:21 PM

Quote:

Originally Posted by WCRiot (Post 141314)
No one has a reply to my latest attempt?

Todd
Have you tried what I suggested??
Peter

crystallographic 11-20-2017 06:52 PM

Working Curved Channel
 
13 Attachment(s)
Quote:

Originally Posted by WCRiot (Post 141314)
No one has a reply to my latest attempt?

Hi W.C.
Here is one simple method of working curved channel, that is close to what you are doling, with tools you likely have ..... :

1) Make half-channel flanged pieces:
Attachment 44190
2) Select your cross pein hammer for stretching the short leg:
Attachment 44191
3) Hammer the edge of the short leg, holding it firmly against a stout steel block for back up and hitting so hard the hammer rings against the block - but the part does not move. Hitting accurately is essential.
Attachment 44192
4) Curve your piece to match the inside radius of your corner - length of part is two fingers longer than needed, for fitting and trimming.
Attachment 44193
5) Shrink the other flange to match curve and length. Some repeat stretching with the hammer is sometimes needed for the best fit.
Attachment 44194

In many cases the channel is made and arched for the lengths of each side of the opening, with ends left long. After forming the arches the ends are snipped into flanges - leaving the inside wall and leg - and curved around into one corner. That section is held in place while the cross piece is arched, and one end is snipped to match the previous, with the outside wall and leg. And so forth around the opening. When done, the car shows neat clean work with a couple of weld seams in the corners of the drip channels.

Another method is to form the channels to make it around half of the opening, measuring around the outside of the channel. Form the arch like before, but cut out the entire inside "L" or flange for the full corner, and then make the two ends half-arch to the car Centerline. Make the opposie side, fit both and trim, and weld the two Centerline joints, front and rear.

Now, go back and make the four missing "L" corner sections, stretching the legs to fit and welding two butts and one corner joint at each corner.
Done.

Handmade cars like these, below, had their hood and rear lid channels made using these methods:
Attachment 44195Attachment 44196Attachment 44197Attachment 44198Attachment 44199Attachment 44200Attachment 44201Attachment 44202
Hope this helps you solve your curved channel forming problem,

KAD 11-21-2017 02:28 AM

Perhaps you should try Peters approach at this time as it seems like a reasonable way to attack the problem.
It helps for me to see pictures or diagrams of a process this complex done by hand work.
Maybe if you ask nice Peter would elaborate a little more as I would like to see it formed all in one piece by hand methods.
That's a pretty daunting piece to tackle by hand work for anyone I would think.

crystallographic 11-21-2017 03:06 AM

Quote:

Originally Posted by Jack 1957 (Post 141034)
One basic set of hardwood dies.

Attachment 44002

aka "form block" in aviation - after WW2 with car industry starting up again, and with labor migrating from war factory to auto, the technique became "hammer forming" which is different from "Wheel forming" I suppose...

Many ways to skin the same old catfish.

Peter Tommasini 11-22-2017 12:33 AM

Quote:

Originally Posted by KAD (Post 141417)
Perhaps you should try Peters approach at this time as it seems like a reasonable way to attack the problem.
It helps for me to see pictures or diagrams of a process this complex done by hand work.
Maybe if you ask nice Peter would elaborate a little more as I would like to see it formed all in one piece by hand methods.
That's a pretty daunting piece to tackle by hand work for anyone I would think.

If I could draw on the computer I would show how it's done , BUT....I would not know how to even start:eek:
the only thing I can suggest ....
I have cameras in my shop.... no audio (not just yet) but I could try to record the way to do it... and then with a bit of help from my son I could copy it on to a USB stick and send it to who ever is interested:D
Peter

cliffrod 11-22-2017 07:31 AM

Quote:

Originally Posted by Peter Tommasini (Post 141464)
If I could draw on the computer I would show how it's done , BUT....I would not know how to even start:eek:
the only thing I can suggest ....
I have cameras in my shop.... no audio (not just yet) but I could try to record the way to do it... and then with a bit of help from my son I could copy it on to a USB stick and send it to who ever is interested:D
Peter

Not sure that the original poster has an English Wheel.

Whether or not he does, the way Peter uses a wheel is not like the videos and demos I have seen. after watching Peter manhandle his wheels at RockHillWill's shop last fall, all I can compare it to is how people are supposed to use a screwdriver and how every one of us really uses a screwdriver. Most use an English wheel passively. Peter pumps, twists, lifts one side of the metal while pushing down on the other- whatever it takes. At times, it looked like he was going to flip the wheel over when he was making the metal do what he wanted it to do. I'm not kidding. It wasn't the calm back & forth while holding your mouth funny like most pics show....

Think about how you put something in a vise, then twist and pull and push against it to bend it, often to the limit of how the bench is attached to the floor or wall. The same thing happens in the wheel. The difference is that when done in the wheel the metal is rolling back & forth instead of staying in one place.

By cocking the flat/square lower wheel so it isn't parallel to the upper wheel, you can use the chosen higher edge of the lower wheel (which is now all that is part of the lower wheel-metal-upper wheel contact group) to create the desired line in the metal. Move slowly to follow your desired line while pulling down or pushing up as needed. It works very well and is not difficult. Peter's English wheels have a screw on each side of the lower wheel saddle to make such adjustment simple. But you could easily shim an axle end on a non-adjustable saddle to achieve the same thing. I ordered my flat lower wheel/anvil from Hoosier with different radii on each edge for exactly these reasons. No bead roller here yet.

Whether or not you have an English Wheel, like Kent said, there are many ways to achieve the same result.


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