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Old 05-08-2009, 08:32 PM
Kerry Pinkerton's Avatar
Kerry Pinkerton Kerry Pinkerton is offline
Join Date: May 2009
Location: Near Huntsville, Alabama. Just south of the Tennessee line off I65
Posts: 7,907
Default The Art Deco Imperial Project - Part 17

Been working on the engine for a while but this week I decided I wanted to shape some metal before I leave for the Bugly meet. The door is next in line. I shrunk some 18 ga angles to match the fair curve that I lofted from the grill to the back of the door and welded them in place. To make a Burt Buck, I sheared some 1/2" strips of some 5051 aluminum (I got some from Frigo when I got the 18 ga and us it for misc. stuff.) I wove it into a grid that lays on top of the angles. At the top, I bent the strips to mate up with the armrest portion of the top of the door and tucked the strips under the door top and taped everything in place.

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Some aluminum tape and here is the Burt Buck. I needed about 6 feet of tape off a new roll, the second so this tape goes a good way.

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After the fiberglas tape was applied, you can see how the door side transitions from a pretty tight radius at the back of the door to a large radius at the front.

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This is a fairly low crown panel all over...not a lot of shape anywhere. I was able to use 2" wide transfer and fiberglas tape.

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I'm going to try and whip this out tomorrow. It LOOKS easy but it will probably kick my butt.... I'm going to try it in one piece.
Originally Posted by jhnarial
...How will you attack the top of the door?At one point on the top of the door there's a 90 degree angle.I am not sure how to do that with a English wheel....

Beats me....

Seriously Johnny, my thinking is to shape to the flexible pattern before I worry about the tip. I'll then mark the tip "line" on the back side of the panel, and work it over using a combination of the tipping wheel (probably the one in the Hoosier tipper rather than a Pexto tipper. Also work the rolls with the gokart slick, various lower dies, and some hand work. That's the plan. This and 5 more will make an even half dozen door skins I've ever done.

That said, one thing I learned in the Army was that plans go to hell with the first problem so I expect to be OBE. (Overtaken By Events)

I REALLY like the whole Burt Buck concept. It works very well, is easy, cheap, and most important, it lets me pull a rough flexible pattern that SPEAKS TO ME! Hard bucks don't. AND it lets me 'see' what the panel will look like.
Kerry Pinkerton
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