Metal Shaping. How-To Use Cheap Tools To Build A Complicated Patch Panel.

today we are working on the 1936 Chevy the goal for today is to do something about this mess here so we're going to have to build a patch panel to replace all of this as this is too far gone to repair so here we are straightening out the edges on the surrounding metal it's important to start out with repairing any damage in the area before we start making our patterns or anything else I'm using a flexible straight edge to check the edge for straightness find that works really good for getting a visual on where the metal is at and yeah like I said it's pretty important to get get everything in the right spots before you start kind of planning to build a panel so that's why we're doing all this first kind of a hassle but if we don't do this now then we're just going to be putting a panel or building a panel to the wrong shape which is just going to cause a lot of issues later on [Applause] so I've gotten the surrounding metal roughed out so it's at least close but this is all just like a mess in here you can see it's it's caved in a fair bit and there's nothing I can do about that there's stuff weld on none of this in this area is salvageable I did check the actual wheel opening to the other side or the good fender and it's uh it's there it's the same can't wait to read the comments on this one uh it almost looks wrong but just uh just staying in there and uh you'll see there is a somewhat of a method to this and it's really only temporary unless it works so the main reason for sculpting this Fender is of course to troll the internet but it does have secondary purpose as well I find it's very helpful to have a three-dimensional shape on the side that I'm actually fixing or repairing rather than just pattern off the other side if I did just do all my patterns off the driver's side that'd be more than enough information this just helps me to have something that I can fit the panel to and this is also very helpful if you're building a custom panel that doesn't exist you can test the shape with Bondo before you go to all the trouble to actually build it out of metal or make a wire form or whatever so I'm going to make a template of the patch that I need for this I'm using cheap masking paper from the hardware store and some some masking tape um if you want to do this more accurately I think tape probably works better but tape is expensive so I just use a combination of both and what I do is I lay the paper on and then wherever it wrinkles up I make a cut and then re-tape it and that represents a shrink or whatever has to be done to the panel so I just go along and cut and tape and whatever and that's going to conform the the pattern to the shape of the panel and then that's going to give me a lot of information that I need and so it's quite helpful that way I used to just randomly cut out a rectangular metal and just start beating on it and trying to get it to the shape and I find even though you do you will eventually get it it just wastes a bunch of time and material so making an accurate pattern is extremely important in actually building a panel possibly more important than than shaping the panel itself so whatever you can do to give yourself information before you start hammering metal is is definitely an asset for sure now I like to make my pattern about three quarters to one inch larger than the size of the finished panel and what that does is it gives me a little extra wiggle room for shaping the panel and it's also difficult to shape right up to the edge of a panel so I just you know work the panel and then once I'm done with it I trim off that excess I don't want to make it much bigger than an inch of extra material because that's just extra material that I have to work and shape so it just makes it more difficult but if you notice in the video here I'm making two patterns actually and the reason for that is because I'm using the paper as a guide to decide what is going to be the best course of action for shaping this panel and what the direction I'm going to go and where I'm going to start and and where I need to shrink and where I need to stretch so so this one you saw we did our splits this way and pull it around this way whereas this one we made our cuts at the top and what this is doing because this is telling me which direction that is going to be easiest to start shaping and metal in so if we look at this first one we made here we can see that there's hopefully you can see anyways can you see if we look here where we made our cuts there's a lot more of this paper overlapping and we also had to make our Cuts fairly deep into the paper here we got to do what we want whereas if you look at the second one that we made you can see there's a lot less overlap where we made our Cuts so what that indicates is the slices are indicating shrinks and so this is telling me that this piece needs less shrinking and less shaping in order to get the shape so basically the paper is just acting in place of what a piece of metal would do we're going to be concentrating our shaping in this area and we're going to be doing shrinks here along the top and then we're going to be stretching the metal to the center here and we may have to do a couple of shrinks down here just because things never quite go exactly as planned but if I went with this this route and I I started shaping the metal in this direction down at the bottom here it's going to take a lot more work to gather all of this metal down here and I would still be doing stretching through here but I would have to do a lot of shrinking along this Edge in order to get this to pull around so and again this is uh I'm just blowing smoke here so we may have to completely change this plan but for now the paper is telling me that I'm gonna have less shaping to do if I concentrate most of my shrinking up here another way to confirm that is I have my piece of metal here cut out and when I cut out a piece of metal I don't want to add a lot of extra material than what I need I have to add some extra to the bottom for the body line and the wire Edge but I don't want to leave a bunch of extra material that's why it's very important to make pattern because the more material I leave on the edges the more shaping or the more metal that I have to actually shape if I'm just going to be cutting it off later I'm just creating more work for myself and I'm wasting materials the more material there is on the panel the harder it is to you know fit shape you want so um we lost track of what we were doing here but anyways let's see we went with our first pattern and we were going to be doing all of our shrinking down here well if I lay this piece of metal on here again this is going to be our starting point and we're going to be doing all of our work through here well you can already see that the metal is only touching a fraction of the surface here whereas if I place this on here like this there's a lot less rocking so it's already contacting more surface down here and what that's telling me is that there's less shaping needed again if I go and Shrink up here and stretch through here rather than trying to get all this metal to come around down here and pull this shape in so it's going to be in theory easier to pull this way but that's just another test I do hopefully some of this is is making sense because I'm confusing myself but anyways uh so this is our our second pattern that we're going to go with where we shrink along here and so we lay this on here and you can see the rise in our pattern here so again we're going to achieve this rise in the panel by stretching the metal all through here to see that all needs to be stretched and up here we're going to be shrinking The Edge and that by shrinking The Edge it's going to help to pull all this around it's easier to stretch metal than it is to shrink the forces of contraction are greater than the forces of expansion so because we don't have a lot of special fancy tools or anything like that we don't want to do a lot of shrinking because it's just well it's more work for us if we had better equipment then it would be less work but we can achieve stretching just by hitting the metal with a hammer so um that's kind of what we're going to do there but we're going to begin Now by by shrinking this Edge while I'm here and that's going to help well you'll see you'll see what happens when when it happens I guess if it happens so I'm now using a homemade tucking fork in order to do a series of Tuck shrinks basically what this is doing is this is putting a series of I guess you call them Ruffles in in the metal and thus uh shrinking it to then as they are hammered flat the metal collapses in on itself on kind of a molecular level and shrinks the metal so um if you want to see more on this I believe there's quite a bit of information on talking Forks on the internet and on how to build them uh you can check out everybody make it custom has a video on YouTube that goes over quite well and kind of demonstrates I thought it was interesting as I'm hammering these flat you can actually see in the sped up footage how the metal is is collapsing in on itself and it's not something you can see just at regular time other than seeing the panel take shape but in sped up version you can you can really see the metal as it as it compresses and shrinks so it's kind of interesting but I'm going to do a series of of Tuck drinks along this and I'm going to be over shrinking it because in order to smooth out all these tucks I'm going to have to go back in and planish it or English wheel it and that's going to do a bit of stretching in order to get that smoothed out so we overshrink first and then as we smooth it out it kind of goes to the shape that it needs to be the more pronounced the the ruffle or whatever the more effective the shrink will be so again if you look you can really see as I'm hammering this down just how that metal is literally collapsing in on itself and again that that's not visible to uh in regular time but it's it's interesting how it shows up in the time lapse as with a lot of this stuff it's not instantaneous it does uh it does take time you can't just go in you know with uh with a lead Fist and just expect to hammer out a panel immediately it it's all very slow process so that's why I think speeding up the footage kind of gives a better example of what exactly is going on and what's happening to the panel because if it was all in regular time you wouldn't be able to see what's going on um unless of course I had a lot of uh hundreds of thousands of dollars worth of equipment and then it would happen very fast and as you can see my cat agrees with this foreign foreign so first and most importantly I just want to let everyone know that I have absolutely no idea what I'm doing in case that isn't already obvious um but the the nice thing about all of this is that it is a very slow process so anything that happens or goes wrong you can just keep correcting it and it takes you know a fair amount of time to actually make a mess of things and even then if you're determined enough you can usually sort it out so what I start out with is a fairly High Crown die and I'm just trying to smooth out all the lumps that we put into it from the rough shaping and as we progress we'll we'll continue to to work it and whatever but we just kind of wheel in a variety of directions as needed and again this is all a very slow process there's not really I don't think an exact science to it maybe there is but so uh one of the most common questions I get asked is how long uh something takes whether it's a repair or something that I'm building and the answer to that is that if you are concerned with how long something takes then you need to find a different pastime the thing with this is is it uh you you get faster the more you do but if you go into something with the mindset that you're going to get it done in x amount of hours then you're going to run into a lot of issues and you won't be happy with the final result if it does in fact ever get finished so this is something that I'm of course guilty of too so I if I'm doing something like this I just decide that I'm going to do it and it doesn't matter how long it takes and I'm not going to keep track of how long it takes because that's irrelevant I need a patch panel for my 1936 Chevy Fender which these fenders are non-existent as are patch panels for them so if I don't do it then it's not going to get done so it really doesn't matter how long it takes because you know like I said it needs to be done so we're just going to get it done and that is my approach to doing this type of stuff is I don't care how long it takes so what I've done here now is I've switched over to a lower Crown die for the bottom and reason for this is I noticed the upper section was beginning to curl over a bit too much so what I'm going through and I'm flattening that back out again um this is why it's it's nice to use the wheel and use all these hand tools because you can really kind of go back and correct all the stuff fairly easily and it's also critical of course to continue to recheck our panel to our patterns at regular intervals this just really helps to confirm that we're going in the right direction and if there's an area that's not fitting right we can focus on that area and just continue to work it um I'm again going to an even lower Crown die because I found that there's still a bit too much curl in the top so I'm just really trying to flatten that back out and correct that and then we'll move up to a higher Crown die again once we get this uh this flattened out a bit better the uh the lower Crown die that you use the the smoother the panel will be but the higher the crown uh the faster you can put shape into it so it's kind of a balance between both of that I believe now we are back to a higher Crown panel we're trying to stretch out the center a bit more and and get it back to the right shape so this this is again all very tedious but uh unfortunately necessary I guess so you can see it is kind of starting to take the shape of something but when we uh reference it over to our uh our pattern here We Lay this on let's see I can still push all this down in the center here so it's telling me that we're still low all through here so we're going to need to do more stretching in here so instead of just you know doing this exclusively on the wheel we're going to kind of go back and forth between using our sandbag and our Mallet to put a bunch of lumps in it to stretch it and then we'll smooth that out reject it and just keep going back and forth until we end up with the desired result rather than trying to just achieve all of it all at once thank you foreign foreign thank you foreign Peppa pigs foreign as though I have the shape now um I taped the template over top of it and it all feels fairly tight on here now there's no more there's a little bit here but when I put it on the uh the panel itself there's also a little bit here so this is more of a deficiency in the in the pattern itself than the actual panel and I've also made gauges for this profile here and when we check that to the panel you can see it's all pretty well bang on there foreign what all of our information is telling us is that this is now the correct shape or as close as we're going to get it so now I'm going to begin working on this this body line here I'm just trying to figure out the placement of it right now so that we can get that installed for those of you who don't believe me here we are taped over top of the fender and you can see we still have the same looseness in this area so again that's a deficiency in the uh pattern here which is probably where a tape template a full tape pattern uh kind of like the one race lean makes that would definitely be superior to this in that regard but either way based on all the information that we've gathered this panel here is now the shape that we need so I'm okay with that so for figuring out the placement of the body line what I did is I laid my pattern on the fender and I took a X-Acto Knife and I made a bunch of cuts where I could feel the body line through the pattern and uh then I laid the pattern over top of my panel here and then you can see I made I just took my X-Acto Knife again just made a bunch of slices which transplanted onto the metal and now I'm just using blue fine line tape and I'm just laying out where I think it's going to be and the nice thing about this is I can keep peeling it off and and putting it back on and changing this and standing back and looking at it until I get happy with this shape then when I get happy with this shape I can mark it out and then go over to the bead roller just gonna use this hardened pin with a slot cut in it to tip the edge over on this piece here trick with this is just to do very small increments at a time you don't want to try and do the whole thing all at once we'll put a big wrinkle or something in this which is unpleasant because I don't think you need to watch this in real time so I'll hit the time lapse here [Music] foreign [Music] [Music] [Music] so this is where I'm going to call it on this one I think I think we got sort of to where we were trying to go on this which wasn't very far but you see there's no collapse holding it right now it's just got a masking tape keep it in place and it's all fitting very very nicely all through here it's all fitting flat to the Bondo buck so we know that we've achieved the correct shape on this and that's kind of the the whole goal here was just getting the shape right um we could have got a perfect mirror finish on it and had it be you know half inch low in the middle and it would have welded in fine and whatever but it never would have looked right so I think um all the time we spent doing the Bondo Buck making our paper patterns making our templates or the profile all of that helped us immensely with this this process so there's not really anything I would have done differently on this actually so I think for what we were trying to achieve um it all went fairly well and all the just understanding where we were trying to get by by spending the time making this Fender the right shape getting our patterns off of it and then checking our piece constantly lead to that shape is what allowed this all to kind of come into place that was more critical than the actual shading part when we got to the shaping part all we were doing is we're either shrinking or we're stretching so there's only two different things that you can do to make the shape that you need but if you don't have the information and you don't understand you know what you're trying to achieve here then all that becomes very very difficult and you still see the surface quality isn't uh fantastic on this but you can still see you know our tattoos where we did our shrinking here but I I really can't even you know feel that with my hand and we have to keep in mind that this is all going to be getting welded in and then planished and and finished out so by the time we do all that that will take care of these surface imperfections I'd rather you know just finish out the rest of it by hand when during the welding process and whatever rather than try and waste time trying to chase it out with our China wheel it's not uncommon for this thing to uh to you know twist or Flex the wrong way and suddenly you've got a huge imperfection in in your panel that was almost finished and not that it can't be repaired you know metal you can do anything with it you can just keep shaping and shaking it forever but I would get pretty frustrated at that point and I would probably just walk away from this and as we all know having our patch panel is ruined by cheap tools is a major part of the whole communist agenda so okay we look at this thing this is not exactly a Precision instrument by any means and I I mean you can you can do all kinds of work to this you can brace it and you see just how crappy these these wheels are and we get we could polish this all out nicely and and whatever and it and it would probably work better but same time like how much time do you want to invest in in this thing as you can see it does get us the shape that we need and that's really for what I do the junk I work on you know I don't uh I don't need anything beyond that so it uh I just wanted to I just want to build cars I don't want to don't want to try to change the world so that's uh that's that's what we got there and this means a little tweaking and whatever but it's more or less ready to weld in so if you want to see uh that process let me know and we can do a video on welding this in and finishing out the welds and all that I have to run into the City and get argon still for my TIG welder but that's another problem for another day and then there's also a wire Edge that has to go in here so we weren't you saw me fold this under but there's actually another step there still so um what has to happen is the wire Edge is going to fit in here so we have to take this this 90 that we bent and then we have to again use our tool here and fold that 90 up into a u shape and then we'll insert the uh The Wire into here and then fold the rest over and normally I just fold it over by hand with a hammer and Dolly but I might build a tool for this because it's a pretty large patch but we'll see how ambitious I am but that would all be for a future episode so if you want to see all of that and the welding and whatever again leave a comment let me know but for now I'm gonna burnt out on this and I got enough done here for a video so we're gonna call it there well thanks so much for watching everyone and just a little update here uh about a week or so ago I made a community post here on YouTube and let everyone know that there was a imposter so if you didn't see that what's happening is someone is pretending to be me on Instagram and Facebook and on Facebook they're also stealing my videos and re-uploading them onto Facebook so I am not on any social media other than YouTube and I have no intentions of branching out to other social media especially how so a lot of you um reported the the post or the the account on Facebook and Instagram so I thank you all for that and taking your time to do that uh like I said I don't have accounts on there so it's difficult for me to do that but I did eventually go through the entire uh strenuous process of figuring out how to report things on Facebook without an account and filling out all of that and basically what it turned into is a very frustrating situation where well let's just say the The Imposter account is still up despite being reported by many of you and also for me you know sending a report in as well and the problem it seems is that there are no actual human beings running the whole Facebook reporting situation it's all in AI so there there's basically I ended up uh just in a in a loop of a a conversation with a robot who saw nothing wrong with somebody ripping off my content and using my name even though it's quite obviously not me and when I check back there now they actually have more followers again on Facebook and Instagram so again I'm not on there so do not follow them and do not watch any of their videos do not even interact with any of their posts as it only serves to help them it seems and I'm not even mad at whatever whoever's stealing it it's obviously someone in some foreign country that doesn't speak English so there it seems to be fairly common now but the problem is the platform just has no desire whatsoever to remedy the situation and when you're talking to a robot they you know yeah it's what I'm saying is is to boycott Facebook and Instagram not that I anybody's going to listen to me or I know what's addictive and whatever but uh I would strongly encourage anyone who has an account on either platform to delete their account and boycott them as they are literally garbage at least with YouTube If you sift through all the garbage on YouTube there is some value in what is going on YouTube whereas Facebook and Instagram are just serve as something for narcissists and idiots to congregate and spread their idiotic ideas around meanwhile the people running show get rich and contribute nothing to society so that is my rant on that on that note we will sign off and we'll see you again soon with more chaos and we'll not be seeing you on Facebook or Instagram ever thank you for watching foreign

Channel: Carter Auto Restyling

Views: 199,012

Keywords: Hot rod, rat rod, carterautorestyling, carter auto restyling, diy, bodywork, autobody, rust repair, fixing rust, fixing dents, dent repair, big dent, mig welding, tig welding, 1947-54, classic trucks, antique trucks, barn find, patina, classic cars, antique car, chevy, gmc, metalwork, fabrication, sheetmetal, patch panel, rusty, rusted, dented, tri five, advance design, 1936 Chevy Truck, English wheel, Bead roller, fender repair

Id: 7oyXvign-TY

Length: 41min 6sec (2466 seconds)

Published: Sat Apr 15 2023