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  #11  
Old 06-05-2016, 08:52 AM
custommetal custommetal is offline
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Robert thanx for all your time posting and the detailed explanations. I use mahogany decking material for a lot of my form work. Cuts well and is hard enough you can't drive a nail into it. I had posted about a month ago where I used mahogany for the form and a cnc mill to flow form a metal sheet into an insert for a 56 Chevy truck front bed panel. Your posting have been a great help.
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  #12  
Old 06-08-2016, 06:01 AM
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MP&C MP&C is offline
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Thanks for the input guys. I think I'll definitely need another material when my supply runs out, I'd hate to buy that stuff new..



Next task on the list is to add the semi-circular relief areas into the new cowl repair panel..



A suitable piece of Phenolic is cut out, notched at the bottom for "vise support", and used a roloc sander and drum sander to add the relief area in the "hammer form".



Here's the Vise support shown in action... should remain nice and stable through all the hammer action..



Centerline of the hammerform marked, as well as on the vise, to better align our new cowl..



Door skin hammer will be used here to provide the radius, this one was touched up as the factory radius was a bit too large.



Tried it on one of our scrap pieces first..



Back side..



Front side and comparison to the factory version





Action video showing the process:


https://www.youtube.com/watch?v=3Taw...?v=3TawUVtIl5w
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  #13  
Old 06-08-2016, 06:20 AM
axelkloehn axelkloehn is offline
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Great video, thanks for showing!
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  #14  
Old 06-08-2016, 06:53 PM
Steve Dussemberg Steve Dussemberg is offline
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First let me thank you for the very helpful information. You've done an amazing job and the project is certainly in very capable hands. For an unexperienced person like myself these kind of information are extremely valuable. Many many thanks.
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  #15  
Old 06-09-2016, 12:13 AM
Stretch Stretch is offline
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Thank you for the info Robert - I picked up some very useful tips!
Matt
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  #16  
Old 06-09-2016, 12:23 AM
L ee L ee is offline
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Good work!
Thanks for posting
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  #17  
Old 06-09-2016, 05:35 AM
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That came out great and loved seeing the video too.
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  #18  
Old 06-09-2016, 10:48 AM
scranm scranm is offline
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nice work!
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  #19  
Old 06-09-2016, 12:07 PM
crystallographic crystallographic is offline
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Very nice part - and loved the film.
Still smiling about that film .... !!
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  #20  
Old 06-09-2016, 05:38 PM
snedboy snedboy is offline
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Excellent tutorial as usual. I can't believe how fast you can hammer. That must have taken years to learn
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