Well, having messed up my third "LOCOST" bonnet, I'm thinking long and hard about the next attempt. The third attempt has been the closest fit, but the grade of aluminium that I asked for, (can't remember which, but the advice came from this list) didn't exist according to my supplier. The stuff I got was very hard, and using the tried and tested soap & torch annealing method, did nothing to the hardness of the aluminium, it did produce some very nice undulations though!

So as I turn my mind to spending yet more money on this "Budget" car, can any of you who have actually made their own bonnet out of aluminium, tell me what grade and thickness you used. Also, how did you form the side chanells neatly? I don't have a sheet metal bender.

Many thanks in advance, Ian.

Use one of your earlier attempts as a template to get somewhere near the shape. If you use half hard as in the book you don't need to do any annealing. Mark the centre line of the bonnet and the centre of the scuttle and nosecone and line them up. I taped mine with some duct tape to hold it in place. Push the ends down to start the bend and don't let the sheet move off centre, then get your ratchet strap(s) and secure round the bonnet area and wind it in till it touches the side panels. Draw round it and trim off the excess or leave a bit to make a flange, but if you use 16g you don't need one. Mine worked first time like this and we made several more using the same method.

Thanks Pete. Will order some 16g half hard ali and see what I can come up with!

Regards, Ian.