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Old 05-08-2009, 09:32 PM
Kerry Pinkerton's Avatar
Kerry Pinkerton Kerry Pinkerton is offline
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Join Date: May 2009
Location: Near Huntsville, Alabama. Just south of the Tennessee line off I65
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Default The Art Deco Imperial Project - Part 17

THE ART DECO ROADSTER PROJECT
3/24/08
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.
Quote:
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.
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