VW panel van replica kart build

[OzFab]

In all seriousness, I once saw Jesse James create extension panels for a Toyota Celica by folding a sheet then walked along it to create a perfectly contoured shape...

If you have a sheet metal folder, it's easy. If you don't, two lengths of angle clamped together will work to create a straight(ish) bend. After you've made the folds, simply wrap it around a large pipe

 

[fattony]

In all seriousness, I once saw Jesse James create extension panels for a Toyota Celica by folding a sheet then walked along it to create a perfectly contoured shape...

If you have a sheet metal folder, it's easy. If you don't, two lengths of angle clamped together will work to create a straight(ish) bend. After you've made the folds, simply wrap it around a large pipe

That is pretty much what I did. well wrapped and then hit with a hammer and chisel a few times. As I said I will try it again. And I do have a small folder.

And lads there is not much too bending metal. Its not skills you see it is a willingness to try, and try I do. I have yet to get anything right but close enough will do.

I make everything out of cardboard and then sheet. if you want to see some metal forming skills check this guy out.

http://retrorides.proboards.com/thread/70135

its long but if he hasn't made the shape you need, you probably dont need it.

 

[OzFab]

That's a pretty cool thread, there's some nice work there; thanks for sharing

Not to toot my own horn but, as a panel beater, I know & have used a lot of those tricks; everything is easy if you have the correct tools & they don't have to be big expensive tools either...

 

[firemanjim]

Disgusting isn't it?
He could just roll over it with a truck and it'll look good.
That's not fair!

For the side panels I'd cheat (because I hadn't been kissed by talent that often )
that is, flat side panels and a matching thinwall pipe section welded on for the rib.

'sid

Pretty slick idea 'sid..... or maybe it would be easier to fiberglass the rib section on ,like 1/2 or 3/4" pvc split length ways and "glass to hold it on and contour the right shape for the rib. Im just guessing or tossing out an idea. This is the kinda stuff I want to get into..... You're doing an amazing job 2coolTony ......

 

[fattony]

Well I wasn't really happy with how the side panel had worked out so I decided to have an other go.
I had thought of using a cut pipe ,fiberglass but I want to try and make it all out of steel as I'm trying to learn the skills I will need to finish the full size model.
I picked up some waste metal , happen to come across a big U shape which was handy. and made a simple press of sorts. I had a little porta power Body Repair Kit (4 ton) that I bought years ago to do one job and never used it again.

I made up a test piece, I went a bit far but it but it looks a lot smoother that last weeks effort.
I was happy enough with the result that I went ahead and welded it on.

I little worried about the corners but one step at a time. Not to worry Its only a toy after all.

 

[itsid]

Great,

If I only had some spare money at hand, then I would kindly ask to just make another one!

That is so cool!

'sid

PS Indeed, that looks much better than your previous attempt and much better than a welded on pipesection GREAT WORK (picture that to be size 7 bold )

 

[firemanjim]

Thats AWESOME! If I did not know better, I would tell you that the last 2 pics are of a bus being restoed.... amazing work dude! You should probably make a few of them karts . You would make a killing with the die hard bus guys..... its a MUST HAVE mini bus....

 

[fattony]

Sid the time this is taking, no amount of money would pay me to produce them. Anyway it wouldn't be the only one then

Got the other side done. Not going to bother with cargo doors.I don't think the kids will notice,and I want to get it done for christmas. The rest of the body is going to be tricky so its going to take some time. Not sure whether to bend the corners before or after I press the rib in to it. Also looks like i'm going to have to reduce the size of the deck lid or the hinge will fall in the middle of the rib.

 

[firemanjim]

Could you make a "buck" (?) out of wood the shape you need the corners ,then shape the panel around it? I've seen the process done first hand and it was definitely for someone with real talent to do. Just figured that would be up your alley. Its a pretty cool process if you haven't seen it.... but seeing your work,I'm sure you're waaaayyy ahead of me.... lol

 

[itsid]

Sid the time this is taking, no amount of money would pay me to produce them. Anyway it wouldn't be the only one then

But I'm on another continent.. no one will ever notice

Got the other side done. Not going to bother with cargo doors.I don't think the kids will notice,and I want to get it done for christmas. The rest of the body is going to be tricky so its going to take some time. Not sure whether to bend the corners before or after I press the rib in to it. Also looks like i'm going to have to reduce the size of the deck lid or the hinge will fall in the middle of the rib.

(CAUTION: nitpicking ahead)
there's a little kink in the end of the rib

I don't want to be pedantic, but seeing what you did so far, that catched my eye.

I'd go for first rib, then 'buck' or maybe heat bend on a pipe and reworking the rib again. *shrugs*
but what do I know!

'sid

 

[fattony]

(CAUTION: nitpicking ahead)
there's a little kink in the end of the rib

I don't want to be pedantic, but seeing what you did so far, that catched my eye.

'sid

You are correct Sid, there is quite a few bits that need to be addressed. I might do some of that in the evenings this week. There will be a certain amound of prep work before paint too, to sort anything that my hammer can't fix.

I found a few things that dont measure up and I am not too happy with but I will sort them out before procediing. Thanks for the feed back.

Not sure about the buck idea. I've never tried it. Its probably alot of work for a one off but I will do some research, Thanks firemanjim.

 

[itsid]

Not sure about the buck idea. I've never tried it. Its probably alot of work for a one off but I will do some research, Thanks firemanjim.

You could always make a second

No, honestly
I'd take a bet that at one point in it's life it will have a bad dent right where you can't fix it with just a hammer, so having a mold handy isn't a bad thing I'd say

'sid

 

[firemanjim]

What Iwould do/try is getting a piece of 4x4 or 4x6 and shape it ,round it to meet your panel needs. Use a grinder to cut away the heavy stuff and a chisel,small grinder, ect to shape the rib. Sand everythingsmooth like for a f'glass mold. Then using a little "heat" and body hammers, start shaping the panel around the buck ,from the bottom up. With the workyou've done already,I have NO doubt you can do it ..... And like sid said,it would be handy to have to fix any mis haps down the road.....
Ill see if i can dig up some videos or some articles published on the process. ..

 

[fattony]

I will see what timber I have lying around and borrow some big *** clamps. I sorted out some of the issues I was worried about last night. Lining things up, I had to move the panel side of the doors out so they were straight with the side panels. There was a light dip were they met and trying to avoid using buckets of filler.
I also installed the dash, I still need to finish the ends of it but you get the general idea.

 

[Oxymoron]

This is just so cool. Good on ya', bro. I hope you hit it with a two tone paint job when you're done... wolfsburg style!

I've never worked with sheet metal in this way before. That looks.... arduous You make it look easy though!

 

[OzFab]

Sheet metal is not as difficult to work with as you seem to think; with the correct hand tools (no machines) & a bit of knowledge, you can turn a flat piece of steel into a bowl...

 

[danssoslow]

Sheet metal is not as difficult to work with as you seem to think; with the correct hand tools (no machines) & a bit of knowledge, you can turn a flat piece of steel into a bowl...

And Jesus said unto David, "walking on water is easy. Just start stepping on it like this."

It's that "bit of knowledge" part that seems way underated. I have a hard time keeping flat sheet flat; much less manipulate it into a desired shape.

 

[itsid]

agreed..

making a bowl out of a flat sheet..

Tony, you're talking about that leather-bag-mallet-thing, right?

I think I could make a perfectly useless chunk of scrap metal with those tools and a sheet of steel, not much more

'sid

 

[danssoslow]

I think I could make a perfectly useless chunk of scrap metal with those tools and a sheet of steel, not much more

'sid

You're looking at it all wrong. You call that art!

Like Morgan Freeman would say in "10 Items or Less": same thing, but better billing.

 

[itsid]

You're looking at it all wrong. You call that art!

Like Morgan Freeman would say in "10 Minutes or Less": same thing, but better billing.

You tell me NOW? With all the "art" I've done I'd be rich by now.

but more important:

fattony, any news?
I can't wait to see the front mask

'sid