Hand Formed Aluminium Body

[Nick Jones]

That looks hard to me! You seem to be winning though and it’s keeping you out of mischief 

[John Bonnett]

Thank you all for your encouragement and very kind words. I am finding it difficult both mentally and physically but we are getting through it and with the Coupe Florio next year, a very good reason to press on.

[mpbarrett]

amazing quality work. Do keep the updates coming, it is fascinating to see the body progressing..

[John Bonnett]

51 minutes ago, mpbarrett said:

amazing quality work. Do keep the updates coming, it is fascinating to see the body progressing..

Thank you. Just to amplify my remarks of yesterday, the mental difficulties that I mentioned are not me going round the bend (although probably no sane person would have embarked on this project ) but more trying to get my brain around how the metal moves and what needs to be done in order to achieve the desired result. In some ways, metal is a bit like clay but I don't think the analogy completely fits the situation because, unlike with clay where you can locally work a defined area with no affect on other parts, that isn't the case with metal where whatever is done to one section can affect other parts of the panel quite significantly as with the bonnet bulge for example. And for me, that is the hard bit in trying to anticipate the consequences of the actions but it is great stimulation for the brain which has to be a good thing. And then there is the sheer physical work of manipulating the curved and work hardened panels by hand which for an oldster like me is really taxing but then that has to be good as well. So, the bottom line is that I'm finding this project a huge challenge but I'm loving (almost) every minute of it and cannot wait to see it finished and on the road.

[RogerH]

stunning.

 

Roger

[Mark]

Excellent work John, really great. Undoubtedly a huge project even, for a skilled metal worker. I think you mentioned previously that you didn't really get into shaping metal until you were 60, which really inspired me. I reached the big 60 the other week, and I've not given up on the idea of making some alloy body panels, or even a caterham or Austin 7 type special one day. Keep up the great work.

[John Bonnett]

1 hour ago, Mark said:

Excellent work John, really great. Undoubtedly a huge project even, for a skilled metal worker. I think you mentioned previously that you didn't really get into shaping metal until you were 60, which really inspired me. I reached the big 60 the other week, and I've not given up on the idea of making some alloy body panels, or even a caterham or Austin 7 type special one day. Keep up the great work.

That's really good to hear Mark but do let me warn you that metal shaping is addictive. You might like to have a look at Metal Shaper Tom's YouTube channel. I have had several conversations with him and he really such a nice an modest chap. He is currently building an Austin Seven Special for himself and I just thought this might inspire you even more. 

 

[Mark]

Thanks John, interesting stuff.

[mpbarrett]

john if the ali work hardens as you work can you anneal  it? I know you can do this with copper but it must be difficult with a large piece of ali? Also do you want the final panel work hardened as I guess that will give it more strength?

mike

[RogerH]

Hi Mike

the Ali Alloy sheet can be hardened.

awkward on a large sheet but basically you coat the rear side with a soapy compound and then apply heat 

on the front side and wait forthe soap to turn brown.

If you wait too long you havea puddle.

 

Roger

[RedRooster]

Why does that sound familiar 

[John Bonnett]

11 hours ago, mpbarrett said:

john if the ali work hardens as you work can you anneal  it? I know you can do this with copper but it must be difficult with a large piece of ali? Also do you want the final panel work hardened as I guess that will give it more strength?

mike

Yes, that's absolutely right Mike work hardened is good for the finished panel but the main strength comes from the curvature.

[John Bonnett]

All of a sudden, the front end is getting there. Panels just loosely laid in place but they give form and an indication of how the bonnet will look. The centre section needs a lot of work but I can't proceed without the aid of a willing helper because it's too big for one person to hold.

[RedRooster]

I'm sure your find plenty of helpers for aluminum body work forming, have you tried piston heads? 

 

[John Bonnett]

5 hours ago, RedRooster said:

I'm sure your find plenty of helpers for aluminum body work forming, have you tried piston heads? 

 

It's not a problem Brad, plenty of friends and family but it's just a question of timing and when they can fit it in.

[John Bonnett]

I'm not sure if I have already posted this and apologies if I have but just in the unlikely event that it might be of interest to anyone, here is a link to a very amateurish walk-round video of my project which I made 7 months ago. Whre does the time go?

 

 

[egret]

Lovely video, really gave me a better understanding of the car.  I'm certain it's going to be very special once you're done.

[Escadrille Ecosse]

Very impressed by the work on this car. Hope you get a willing helper soon to assist with those wings

[John Bonnett]

7 hours ago, egret said:

Lovely video, really gave me a better understanding of the car.  I'm certain it's going to be very special once you're done.

Thank you. That's really kind of you.

[John Bonnett]

5 hours ago, Escadrille Ecosse said:

Very impressed by the work on this car. Hope you get a willing helper soon to assist with those wings

Thank you Colin. All being well, a friend of mine who is a master metal shaper is coming round to lend a hand wheeling up the bonnet centre section so hopefully, all sorted. I'll keep you posted.

[John Bonnett]

Progress on the project appears to have been at a snail's pace and not without its fair share of problems but without problems it would be boring so I mustn't grumble  One part of me doesn't want the project to be finished because I'm enjoying the build but another side is desperate to get the car on the road and drive it.

So, where are we? All the sub-panels making up the front wings are now welded together and to my eye, the shape is very pleasing. The front valence is coming along too and will soon be ready for welding. I'm still making up my mind what to do with the centre bonnet section which even by my standards is borderline scrap. I'll keep you posted on that but in the meantime here are a couple of photos bringing you up to date.

Thank you for reading this thread and your support.

[Escadrille Ecosse]

Liking it though

[Mark]

Really comming along, looking good. Excellent work!

[Hamish]

Looking great John. And you put me to shame I haven’t even looked at my fibreglass panels 

my excuse is I’m lazy and fear the lack of space and the mess it’ll all create. 

[RedRooster]

Nice intake scoop on that bonnet is what you need to give it a bit of attitude.