Dr 914's pictures of the steel 916 replica roof in the making Options

[dr914@autoatlanta.com]

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[John Kelly]

That is nice work! An english wheel would be good choice, but it would probably take two people to keep conrol of the panel. One of them would have to be pretty skilled. Getting the shape in the right area would be tricky for a beginner. Any panel that is shaped free form without being restrained will want to curve in directions that are unintended by the operator. Some of the TV shows make it seem like an english wheel is the magic tool for something like this. It is, but it won't do the work by itself. There is a pretty steep learning curve. It can be very frustrating. You have to stretch the areas that need the most shape, and then do lighter stretching nearby to blend the shape into the rest of the panel, all the while controlling the contours in all directions. So, you stretch, and smooth. The metal goes catywhampus on you (because it can) then you have to roll the panel back into the desired contours, check where you still need stretching and start all over again.

Another method would be make the frame, roll the metal to fit side to side, weld, then add shape with a palm nailer. More intuitive for a beginner, because you stretch where it is low until you have the right contours, and the frame keeps the perimeter in line for you. The frame would have to be very stiff to keep from getting distorted by the stretching work.

A mixture of the two methods above would be interesting as well. You would add shape until the panel was getting out of your control, then weld it to the frame and start stretching with the palm nailer.

The hemmed edge? on the rear would not be easy for a beginner either. Nice work!

I think large panels with fairly low crowned shape like that are sometimes harder to do than ones with lots of compound curve in them.

John www.ghiaspecialties.com

[sechszylinder]

Another method would be make the frame, roll the metal to fit side to side, weld, then add shape with a palm nailer. More intuitive for a beginner, because you stretch where it is low until you have the right contours, and the frame keeps the perimeter in line for you. The frame would have to be very stiff to keep from getting distorted by the stretching work.

A mixture of the two methods above would be interesting as well. You would add shape until the panel was getting out of your control, then weld it to the frame and start stretching with the palm nailer.

The hemmed edge? on the rear would not be easy for a beginner either. Nice work!

I think large panels with fairly low crowned shape like that are sometimes harder to do than ones with lots of compound curve in them.

John www.ghiaspecialties.com

Hello John,

I'd like to mention a third method. Wouldn't it be good idea to take the rear trunk lid for the curved regions of the roof ? It should have nearly the same shape as the roof.
If this would work, one could alternatively check the junkyards for properly shaped roofs of donorcars.


Benno

[dr914@autoatlanta.com]

Another method would be make the frame, roll the metal to fit side to side, weld, then add shape with a palm nailer. More intuitive for a beginner, because you stretch where it is low until you have the right contours, and the frame keeps the perimeter in line for you. The frame would have to be very stiff to keep from getting distorted by the stretching work.

A mixture of the two methods above would be interesting as well. You would add shape until the panel was getting out of your control, then weld it to the frame and start stretching with the palm nailer.

The hemmed edge? on the rear would not be easy for a beginner either. Nice work!

I think large panels with fairly low crowned shape like that are sometimes harder to do than ones with lots of compound curve in them.

John www.ghiaspecialties.com

Hello John,

I'd like to mention a third method. Wouldn't it be good idea to take the rear trunk lid for the curved regions of the roof ? It should have nearly the same shape as the roof.
If this would work, one could alternatively check the junkyards for properly shaped roofs of donorcars.


Benno

Geoff and the Irishmen actually sacrificed a 914 fiberglass roof to make the steel one.