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Old 01-07-2017, 06:27 AM
Richard Lennard Richard Lennard is offline
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Default Mirror panel required

Sunbeam Tiger N/S "Rocker / sill" required.
Photos attached show a spare NOS O/S rocker panel.
Please can one of the experts give me a basic plan of attack.
I have virtually all the equipment collected over the last 40 year, stump, good selection of hammers, bead roller, Pullmax, English wheels, gas, tig, mig etc.
A proficient amateur but zero "expertise"!
The issue / problem to overcome, as I understand it, is that the bottom of the door above this panel is curved vertically as well as slightly horizontally.
Most of the pattern panels that can be bought are not, made by me (I want to enjoy the journey, not bothered by the car particularly) and, generally, a really poor fit.
I have all the hand tools for making the required mirror image buck.
The basic panel is slightly double curved in both directions, ie English wheel type stretch required.
Many thanks in advance.

WP_20170107_10_51_17_Pro[1].jpg

WP_20170107_10_51_29_Pro[1].jpg

WP_20170107_10_51_37_Pro[1].jpg
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Old 01-08-2017, 06:56 AM
Richard Lennard Richard Lennard is offline
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Please give me a few hints.
All I want is a general approach to forming this panel, nothing too specific.
ie
1) Make an accurate buck
2) Do the tape thing around outer surface, FSP, to show where shrink or stretch needed.
3) Cut steel sheet, with sufficient excess to allow for shrinkage etc.
4) This is where I need a few pointers!
ie Make it in one panel, or central part (roughly uniform) and two ends formed separately and then welded to the main part.

I dont want anyone to waste hours giving me chapter and verse, just enough hints, so that, hopefully, I wont learn by numerous basic mistakes. (The story of the rest of my life)

Im 65, probably dead soon, so time is of the essence - tee hee.
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Old 01-08-2017, 07:00 AM
Richard Lennard Richard Lennard is offline
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I also have a very large pile of sheets of steel, the correct thickness, to make millions of mistakes and learn by them. I am under no illusions in that department.
Just that, Im ready to go after all the years getting things ready.
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Old 01-08-2017, 09:28 AM
Mike Motage Mike Motage is offline
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#1 The buck
Make some vertical templates
Use a profile gauge to get horizontal shape
Assemble and sand/ adjust shapes until happy

#2. Split the individual pieces to have only one bend
The long pieces can be tough (floppy) until they have some shape

#3 Use templates to check everywhere
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Old 01-08-2017, 12:10 PM
JimRussell JimRussell is offline
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I like Mikes version . I would not use an FSP made over a taped outline of a panel. Instead use a paper pattern if you want to visually see the stretch and shrink areas.
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Old 01-08-2017, 02:21 PM
skintkarter skintkarter is offline
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Sounds like we have quite a bit in common Richard, other than just our firstnames... I have never done anything this complex, but have watched Peter Tommasini's video set and the shaped step you need to make is a lot like the door shut return on the Holden Monaro quarter panel which Peter forms in one piece. From memory, the multiple curved panel steps were started by working in from the edge of the guard with a large homemade flanging plier. Looking forward to seeing your progress and input from others who have been down this track.
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Old 01-08-2017, 03:09 PM
Richard Lennard Richard Lennard is offline
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Like thousands on this excellent forum, Ive read and read, watched, thought about, sketched for years but life got in the way.
But I did persevere with collecting the equipment, much of which I now know I wont use but ive been interested in the classic old gear, namely F J Edwards etc.
Did years of what was acceptable, just acceptable, in the 70s and 80s, but always wanted to do it correctly!
There wasnt the internet then and I had no comprehension of "Shrinking metal", absolutely couldnt happen!!!
Eureka moment when the penny dropped 15 years ago, still not much good at it, but getting better.
My reason for trying to make this sill panel, other than I need one, is, I hope, it involves many of the skills required to make larger panels without the expense of the bigger bits of scrap!
Any further advice will be much appreciated.
I understand the paper template, rather than FSP, makes sense for areas to be shrunk / stretched. thanks.
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Old 01-08-2017, 07:22 PM
cliffrod cliffrod is offline
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You have my respect, Richard. Your motivations make sense to me.

At (almost) 50, I'm 15 yrs behind you and want to do the same things for the same reasons. Our old TR3 needs a full resto at some point. I want to do it, simply because I do. When largely remains to be seen.

The paper patterns work really well to direct work, even for a novice like me. Templates are another great way to guide your work and then hang on the wall.

Have fun and keep us posted.
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Old 01-08-2017, 10:44 PM
Oldnek Oldnek is offline
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Paper patterns are the way to go, they show you pretty quickly in which direction you need to go, as to whether shrink or stretch.

The panel you are trying to make is a pretty tough one for the beginner, but is achievable, depending how patient you are and how much skill you have, doing that panel in sections to make it easier would be better than trying to do it one go, as frustration is the enemy for all of us, and scrap in the bin is not much fun after a while of spending hours to try and finish even the most simplistic of shapes.
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Old 01-10-2017, 05:13 AM
crystallographic crystallographic is offline
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Nice part to make, as it's got some challenge to it.
"What they said" -
paper it out, even as three separate patterns that all key off one set of points.
I might buck it up in steel flange sections, curved and welded to hold the major 5 or 6 joggles and returns.
Work the bulk of it in one piece, and then look at how to add the feisty corner into the whole.
For the details I'd go beadroller and flow forming.
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