Cowl metal work suggestions

More of an art than a science - discuss metalworking and welding here.



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PostPosted: Wed Dec 05, 2018 7:06 am
It's been a while since I posted but I'm in the process of putting my '68 Chevelle back together.

I need to replace a section of metal near the bottom cowl area. I tried cutting new metal then using my shrinker/expander to get the bends but it's not working. Any suggestions on working this metal? I can do two pieces but prefer using just one. The bends might be too complex for my skills/tools. This is the area just in front of the door, under the lower hinges where the cowl meets the rocker. Thoughts?

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Jay - Next project: 1968 Chevelle Malibu

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PostPosted: Thu Dec 06, 2018 12:51 am
MustStangSally wrote:It's been a while since I posted but I'm in the process of putting my '68 Chevelle back together.

I need to replace a section of metal near the bottom cowl area. I tried cutting new metal then using my shrinker/expander to get the bends but it's not working. Any suggestions on working this metal? I can do two pieces but prefer using just one. The bends might be too complex for my skills/tools. This is the area just in front of the door, under the lower hinges where the cowl meets the rocker. Thoughts?

Image


Actually I do have some thoughts.

The first is, two pictures instead of one. Close up is good, but further back wouldn't have taken much more for effort and may have provided a better vantage to offer an opinion.

Another would be, digging deeper to understand what a shrinker/stretcher actually does, because they don't bend and fold.

I could go into a lengthy spiel about how I might do it, but one of my go to options is multipul pieces welded together as you all ready mentioned.

On a simply path, open up a card board box of morning crunchies and see how the box is cut/notched to allow folding. Something like that.
Some use wood forms hammering over the edge, some use equipment to bend break a fold. Clamped between two solid surfaces you can hammer an edge over quickly.

My go to for advice, free wifi and hours googling. As you see from my pictures, further away for viewing and small pieces welded together. I did mention I had some thoughts to give didn't I? Hope they have been of some help to you?
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PostPosted: Fri Dec 07, 2018 3:46 pm
I would get a New repop of the piece IF available and cut the repair piece from that OR better Find a Good Used Part replace whole part OR again cut repair piece from the new used one.
I personally don't Like Re-pop parts most are close to originals but leave a lot to be desired most all are only good for cutting up and using for Patch panels in my opinion.

If a Re-Pop Part isn't available and You have to Hand form the Piece FIRST start by Making a Paper Pattern or template of the part, From that you can make most any part you need Hammer formed over Hard wood or Pieces of steel.

Here is a good video on making a Paper template:
https://www.youtube.com/watch?v=oCRpVqle_ck

From there its just Cut, Bend, shrink and stretch a piece of sheet metal to make most any part you need.

I would Probably start by Making a Wood form of this piece shaped to what you need then sandwich a piece of sheet metal in between two pieces of wood then hammer form the side bends. That corner radius is gonna need a lot of shrinking.

https://www.youtube.com/watch?v=s8eGGrdnSrg

This guy uses steel But Hard wood works good. :knockout:
https://www.youtube.com/watch?v=2KXancgN-fk
Dennis Barnett
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