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Old 01-28-2016, 02:19 AM
Bart Bart is offline
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Default Hammer forming technique

Hi Guys
Just after some advice on making a number plate recess like this? The sheet metal is about 1.1mm thick.
I was thinking of using a hammer forming technique but what do you guys think??
Im interested in what others have done in this situation or similar.
Thanks
Bart



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Old 01-28-2016, 03:48 AM
Oldnek Oldnek is offline
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Appears you are doing a LH Hatchback, very nice. I thought I spotto the makings of the Liftback door.
I would go the hammer form route.
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Old 01-28-2016, 05:33 AM
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Thanks mate, LX Hatchback but close enough

This is the beaver panel I just made, not finished yet but I want the option of putting the number plate recess. I like it plain as it looks cleaner but some people want as per original with recess.





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Old 01-28-2016, 09:32 AM
bobadame bobadame is offline
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I've recently had some luck hammer forming by using a sheet of thick rubber about 1 cm thick along with a big flat faced mallet. The rubber tends to hold the sheet along the flat surfaces as it flows down into the lower details.
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Old 02-03-2016, 10:31 PM
Bart Bart is offline
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Thanks guys
I have tried on galvanised sheet as a test and it didnt come out too well.
I will try again, im thinking of using an air hammer with brass bit or chopping board plastic bit?
Ill see how i go
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Old 02-05-2016, 02:47 AM
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Use some cold rolled steel and you will get completely different results!
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Old 02-05-2016, 06:53 AM
Bart Bart is offline
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Thanks mate I certainly agree.
Only thing is when I start on the roof eventually when I get to it I cant get cold rolled in that size which is around 1340mmx1360mm but I found Blackwoods sell 1500mmx2400mm in galvanised so gal will be difficult to avoid on the big stuff.

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Use some cold rolled steel and you will get completely different results!
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Old 02-05-2016, 10:42 AM
crystallographic crystallographic is offline
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Hi Bart,
I thought I'd toss in a bit of nickel knowledge on this shape:
The offsets I am seeing here give me pause.
The amount of step that needs to be pushed indicates (to me, at least) that you have a "draw" that might need to be addressed, to make those step-downs.
I would almost be tempted to use a 5T or 10T press to shove that shape into/between some cut profiles at each end, glued and screwed to a bolster board base. The pusher can be whatever wood or pipe - but watch those offsets try to tear because of the forced reduction loads in those small areas. Lube may help - some gear oil mixed with Ivory soap flakes is good, cheap, and available.
Sometimes I allow the press to move enough to get to the serious resistance level, and then I split the areas with a mini saw and shove again, making two little welded-in fillers to finish up....
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Old 02-05-2016, 01:44 PM
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ozi jim ozi jim is offline
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For me I would worry that the draw on the sides of the lower sections would pull the rest of the panel around.

I would put 2 cuts with the fen saw at the little wedge shapes on the side.
I would do the whole job in the bead roller including the folds through the middle.

I am thinking the center panel will end up to long because it is taking a shorter path at the bottom, it may require a cut through left to right to remove the excess.
I would put that on a fold line because it would make it easier to clean up.

The wedge sections I would put in last.

First things first you would need a deep bead roller.

In hindsight you probabley should have done the recess earlier in the panel build.

Jim
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Last edited by ozi jim; 02-05-2016 at 01:57 PM.
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Old 02-05-2016, 07:55 PM
Bart Bart is offline
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I agree, I should have done this bit earlier, but live and learn I guess, I'm definitely learning here

This is what I got so far, not too good but I think it shows what Jim was saying about the panel turning.
I feel disappointed in my self but I have to remind my self I'm learning and a beginner.
I will smooth out this hammer form, excuse the rough look of it.
I was thinking of putting this into my pullmax/vibro shear with male die and going for it that way. But from what you guys are saying above maybe I should not??










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