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Old 08-16-2017, 12:11 PM
crystallographic crystallographic is offline
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Default 289 Cobra wheel arch rebuild / repair

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identify the ratty area needing replacement

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pattern the area to the correct contour

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remove section

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make replacement section using a "form block," the original aviation term for the later automotive "hammer form."
form blocks were of oak.
aluminum body is .050" 3003. (1.2mm)

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fit the section to match body contours

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graft in the section and planish (smoothing by light hammering)
I use O/A gas welding for 99% of my body restoration work. (O/A = oxy-acetylene)
Black line is the correct route for the wired edge - the last element of this repair.

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Wire is now hand-rolled into the edge with hammer and dolly, using one pair of the 6in vise grips - with a bit of aluminum under the jaws to prevent marking, so the customer gets a new part and not a used one.

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metal-finished Ford, ready for mechanicals and paint. (I do not file the entire job, as I need only to "check file" areas to reveal / illuminate correct or incorrect contours. Many times I can hand planish with slapper/spoon/dolly and leave a surface nice for the painter.)

This car was sorta rough (rolled over at Sears Point), and got a nose rework, along with headlamp areas, and a number of patches all around. It was a veteran of a lot of track time ....
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Last edited by crystallographic; 08-16-2017 at 02:02 PM.
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Old 08-16-2017, 12:23 PM
Kevinb71 Kevinb71 is offline
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Thanks for sharing. How did you "shrink" the area over the form block? Can you show that?
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Old 08-16-2017, 12:25 PM
longyard longyard is offline
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Nice work as always, Kent. Thanks for continuing to set the bar.
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Old 08-16-2017, 12:26 PM
Maxakarudy Maxakarudy is offline
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Nice Job Kent,

Is the inner half of the hammer form shaped to the reverse curve of the flare or is cut square?
You don't mention how you shaped the curve, I have a particular interest as I'm gonna a build a 289.
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Old 08-16-2017, 01:26 PM
Dave K. Dave K. is offline
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Kent,
Very nice! This is the reason why I call you Professor White!
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Old 08-16-2017, 01:52 PM
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MP&C MP&C is offline
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Beautiful work Kent!
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Old 08-16-2017, 03:44 PM
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Gojeep Gojeep is offline
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Nicely done again Kent.
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Old 08-16-2017, 04:10 PM
crystallographic crystallographic is offline
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Default form blocks and shrinking

Thanks very much guys.

Kevin, Martin -
Shape of backup block (anvil):
If you look at the two blocks stacked above the fender you will see that I kept the backup square because this part is nearly square at the turn.

Method of shrink:
And the charcoal look is the giveaway for my hot shrinking this section in the blocks. It was a bit of a shortcut to shrink back above the turn and force the vertical metal rearwards. The whole "wall" moves back and if you don't shrink the outer edge it will ruffle agreeably, waiting for its turn at reversing into the right shape. So, heat up and whack that arc with a medium-crowned body hammer. No marks if you stay up on the humps. Heat as you need. No more heat or "hot short" happens and the metal fails into bits. 650F to 750F is my limit for this, on 3003. I also hot planish. Blocks in a big vise. I use steel tube as the front side dolly, working from the back.

Shortcuts happen as shapes become routine, and so then why not search about to see if there is a shortcut?? Anyway, I always follow the "recipe" exactly for the first few times - then I am looking for quicker.

Patience is more appropriate for buzzards, sometimes.
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Last edited by crystallographic; 08-16-2017 at 04:15 PM.
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Old 08-16-2017, 08:36 PM
Chris_Hamilton Chris_Hamilton is offline
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Kent, please post more stuff like this.
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Old 08-16-2017, 08:56 PM
cliffrod cliffrod is offline
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So, I've gotta ask-

When significant items pass through my studio or shop, the bits remaining are valued by me even when they have no meaning to others. So far there have been nothing comparable to projects like a real 289 cobra, various Italian machines, airplanes, etc and probably will not be. But, such offcuts like this would not simply go in a normal scrap pile to be discarded here...... I enjoy cool goodies, especially those that happen from real use. Scars are infinitely more relevant than tattoos.

Do such things accrue in your shop to some extent or are they just more weight for the scales at the scrapyard?

btw- fun to see such things. Thanks for posting.
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