Anyone got any tips for the top and bottom folds when doing an ali rear panel.

Got one half made, but I think I could get it a lot better and neater with a bit of guidance.

Pat...

Don't knock over the straight bits and leave the curved bits until last, you'll end up with too much metal at the curve.
Move around the whole panel gradually knocking it over a bit at a time along its whole length. When it is completely over the curved parts will be a bit rough, but you can sort it out by filing any excess and hitting it hard with a hammer. When finished emery and polish.
I found it helped to wedge some bits of wood between the upper and lower rails to give some support, and also clamped some boards over the three faces to prevent them bowing.

David

[Edited on 30/12/06 by DavidM]
Rescued attachment P1010051.JPG

did my whole rear panel by heating it up then shock cooling it makes the area very soft and easy to hammer around. the process is done by rubbing soap over where you want to bend then heating with a blow torch till the soap has gone dark brown its ready then needs cooling rappidly. This may need doing several times you can feel the ali going hard again, can be done in place and makes a very neat finish after pollished up

doesn't that knacker the paint below?

that's a very neat job David.

only if your not careful i made panel in place then took off before it was properly done then painted and also painted with duralac (anti corrosive jointing compound) then put panel on and finished up did a very neat job just takes practice

Smack it with something soft, not a steel hammer, I used a lump of wood !

Clamp with soft jaws, more wood and work your way along gradually teasing the metal over, ie bend a bit along the whole length and return and repeat the process.

Rgds Mark

Did you start with the right shape or just hold up a big sheet, knock the top edge over and trim as you go along?

DavidM - i'll be chuffed if I get mine anywhere near as nice looking as yours.

Thanks so far...

Pat...

And what about the bottom edge?

Pat...

Even if you're not going to anneal the ali can I suggest you warm it with a Halogen lamp or something.

Did mine at this time of year... the metal was cold... it apparently took on the properties of sprung steel!

Till I caught on the cold was the problem it was almost impossible. So I turned the car round so the back was inside the garage, got the radiators on and had my 1000W Halogen on it.... it was like a different metal for the 2nd side!

Cheers,
James

quote:

---

Originally posted by Avoneer
Did you start with the right shape or just hold up a big sheet, knock the top edge over and trim as you go along?

DavidM - i'll be chuffed if I get mine anywhere near as nice looking as yours.

Thanks so far...

Pat...

---

Rescued attachment P1010026.JPG

and
Rescued attachment P1010075.JPG

and
Rescued attachment P1010077.JPG

What thickness ali did you use?

I'm only left with a big 0.7mm sheet.

Should be easy to fold though.

Now, where to get a big sheet of card form............

Pat...

In fact, where can you get a big piece of card from???

Pat...

I used the very thick lining paper you can get from DIY stores, but I had to run a steam iron over the paper first as it kept on rolling up on me.

Geoff

I used 1.5mm thick aliminium, so 0.7 should form over more easily.

I spoke nicely to a local industrial packaging supply company and after telling them what I wanted it for they gave me 6 metres off of a 1200mm wide roll. It was like cornflake packet cardboard, but a bit more flexible.

Most industrial estates have one or two of these companies, so have a ring round and a bit of a scrounge.

David

When heating the ali, does it say pliable when cool or do you have to bend it when it's hot?

Sorry if that sounds thick, but I am from Salford (before moving to the right side of the hill).

Pat...

With the soap thing you are annealing it, so when it has gone cold it will be softer than it was before you heated it.
I did mine without heating/annealing it, but it would make a difference.

David

Cheers.

Will update in a couple of weeks once my rear arches arrive as i have to work out how the top of the curve will meet the ali panel I'll be atempting to do.

Pat...