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Old 06-02-2016, 11:11 PM
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MP&C MP&C is offline
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Default 55 Chevy Cowl repair

Well, after media blasting we have some pitting that was deeper than originally thought...














With so much widespread "issues", let's see if we can come close to duplicating this.. Taking a paper pattern..











Here laid out on some 19 gauge AKDQ...









Trimming...



But I always prefer a test sample first... this done on the tipping wheel





Step dies on the Lennox add the final detail...



Need to fine tune the dimensions, but this looks close. I think I'll make up some dies for the Lennox for better consistency on the good piece..



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Old 06-02-2016, 11:13 PM
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Time to make some dies for the Lennox, here fine tuning the fit..



The outside corners will get some steel added for a sharper detail in the bends..



The 19 ga steel is a good snug fit for the band saw cuts...





The front edge of the panel will be tipped prior to running it through the Lennox, the tipped flange will act as a guide in the slot in the lower die..



Another test run using a straight piece of scrap





Dimensions looking much better.



Enough practice, starting to tip the flange on the good piece.. The tipping wheel on the bead roller bends about 30 degrees and the remaining is done manually with the hand tipping tool..





Flange tipped, some kick shrinking to get the right contour, and we're about ready for the Lennox.. As Kyle was off tonight we'll wait until he returns so we can have two people feeding this long piece through the machine..



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Old 06-02-2016, 11:15 PM
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As we found with some of the practice pieces, when you try to shove metal too much into a hole it tends to pull in from the edges.



So to fix that we'll make up a new bottom die to form the ramp fold fully, then change back to the above die to form the step..





The down side to using phenolic is that it gives a bit where it doesn't make sharp creases well or short reverse folds either. The initial practice pieces wouldn't fold the step down flat, so a wrap of steel was added to the top die to better persuade the step flat...





The upper die holder helps keep the wrapped steel in place.



That did the trick, step is laying down nice and flat..





The front flange hangs over just a bit too much, some hammer action will bring it back in place. Real pleased with how well this turned out..



Some of the practice scraps..

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Old 06-03-2016, 06:52 PM
Kidpaint Kidpaint is offline
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looks great! some useful info about making the dies a 2 step process instead of just a one! how will you add the dimples were the screws are located?
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Old 06-03-2016, 11:51 PM
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Likely a hammer form, a socket with a warranty, and a BFH.
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Old 06-04-2016, 04:10 AM
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Very nice job there Robert.
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