MetalFabrication., How would you make this piece? Options

[mihai914]

Hi to all,

After receiving my welding course from JoeSpark (thanks!!!). I'm going to start to tackle repairing the big holes in the car.

First though I need to make some replacement panels but have never really done any metal working.

If I want to make the exact same part as in this picture below, what would be the best way to proceed.
Should I make the flanges fisrt and then try and bend the whole thing or vice-versa? It's probaly very simple to do but I'm sure there are steps to follow.

Any help is appreciated.

Mihai

[John]

If I was going to fabricate that replacement part as shown in the picture (never mind what else is in the pic), I would start out with a piece of sheet metal and break over the flange (about 3/4"?).

I would then make the other flange with the large radius bend. To make that radius, I would get a piece of pipe that approximates the radius and roll the steel around the pipe.

The last step would be to now bend this Z shaped channel. This is the tough part. I would use a stretcher to "stretch" the first flange so that I could bend the part as shown. To allow the large radius flange to bend, I would cut it as he did to relieve the stress (you can see the slit he made and see the tack welds when he closed up that gap).

It takes a lot of practice to be able to make parts from scratch as this person did. This was not his first metal working project. His parts looked very good and more importantly fit nearly perfectly.

Take the time to work your parts so that they fit perfectly and you will like your results. If you rush the repair, it will look rushed.

Just my $0.02

I wish you the best of luck.