Steel Plate HAMMER FORMING!! Step By Step with Simple Tools - G10 Van Battery Tray
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- Опубликовано: 19 апр 2022
- On this episode of Make It Kustom, I build a battery tray from scratch for my Chevy G 10 van with simple tools and techniques. I Explain building a steel plate hammer form step-by-step to achieve a complex part.
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Sure wish I had had access to vids like this 60+ years ago when I started out working on cars. Wasted a lot of time trying to figure stuff like this out by myself and am STILL learning from you! Thank you.
Everyone over 40 is thinking this👍How awesome RUclips can be providing all this knowhow. And how we should ould have appreciated that in younger days. Idk if the younger folks from today can grasp that. Also driving around on actual Maps.
Thanks for the inspiration.
@@beakittelscherz5419 at 67, RUclips is one of my handiest tools! Things I would have never tried before - like replacing all the suspension parts under the front of my truck - I can tackle and feel pretty confident at completing successfully! I keep saying to my grandkids, RUclips can show you nearly anything you want to know how to do - its not just for watching some kid unboxing toys 🤣
Impressive ...I really liked your video . Thanks for sharing your skills
Right?!!!!
Having worked in heavy industry around simple and progressive stamping dies, I have to say, the automotive battery tray is really a work of art in most instances. As you said several times, 'I don't know why they did that'...well, the various 'tray gussets' (steps inside the tray floor) are there to allow for drainage of battery acid, in event of a charge boil over. The holes are in the tray floor to allow for drainage (both on initial spillage, as well as once it collects in the lower floor). They are made of heavier gauge steel to survive years of acid conditions, and the sidewall (edge) gusseting is there to prevent a heavy battery from 'unrolling' the lip if it moves around. Many also have metal-removal 'cut-outs' to reduce weight. Thus, the product stays light, drained, strong for a very long life (it is NOT a 'planned replacement item' in a car, so its design matches the frame-life-expectation of the car in most instances, at least on older cars). While you think 'hey, HDPE plastic would survive and is strong', keep in mind, HDPE starts softening around the boiling point of water and melts entirely by 350-degrees F. It wouldn't work under a car hood in Arizona in the summer. They were actually designed with a lot of factors taken into account (an acid-impervious steel is NOT cheap, or they would have probably stamped them out of that).
copy, copy Captain. Battery boxes in boot (trunk) of UK vehicles were infamous for rusting, especially where snowy roads required grit. Often built by what looked like scrap angle iron by apprentice welders weilding a torch and cut-off saw. It took a very long time for UK vehicles to get their plastic as good as USA and Japan- huge problems for South Africa, Australia and hot parts of the world, and aircon severely lagged behind US (delco aircon like a meat lockee) and Japan. No idea why they didn't buy a basic older Cadillac aircon license- would have saved UK markets alas UK manufacturers awful leadership.
Damn dude, your reply was as informative as this video. Thanks. I'm actually hoping you make videos (checking your acct after). Edit: You don't ... but I still subscribed in case you ever do.
I'm a pretty skilled autobody guy but I'm absolutely blown away by your talent!!!! You're so down to earth and explain everything so well that I learn something new in every one of your vids. Thanks!!!
ditto metal bashing bro
And people say there’s no young kids around that are taking up this craft . You do amazing work
Very nicely done. I done press dies in the past as well as some hammer dies. Alot of work goes into the making of the die but the outcome is always amazing. Lots of cool tips here. Going have to stop watching all the boogie van stuff. If I don't I'll be looking for one! Haha. Great score on the windows, there are so many good people out there.
Fitzee, we love you and your channel! We have learned so much about shaping metal from you by using simple tools. What you accomplish without expensive tools is amazing!!!
Fitzee,
Between you & Karl , you 2 are my go to sources for uncomplicating the art of sheet metal. I have learned so many great tips , tricks & shortcuts from the both of you.
Thank you both for being the fountain of knowledge of DIY sheet metal fab.
Rick
Between the two of you, at least we have both coasts being represented! 😉
Fitzee and Karl are my 2 favorite fabricators on youtube😁😁
I read the first two sentences and it was happening in your voice. I said "i bet this is fitzee" you have a unique dialect, even in writing
I am a woodworker and can appreciate your use of files, and layout methods- you are a true craftsman! thanks for the videos very entertaining!
When I was a kid I wondered why there was shop class in middle and high school. I loved it more than most so don't get me wrong but it was a peg that didn't seem to fit. Now I realize it was to instill the appreciation and pride in creating something. I had it as long as I can remember but it was there for the kids who may never be exposed to that level of satisfaction. I hear nowadays these kind of classes are being removed from many schools and that's terrible
This video alone,has saved me so much money,I’ve got a bead roller now,and was going to get pneumatic planishing hammer,but not now,THIS is the best video for me learning..thanks man 🤙
It would be amazing if you and Fitzee could collaborate on a project together!Beautiful craftsmanship Karl! You , like Tony, have that ability to teach and keep our attention till the end of the lesson!🇨🇦
Look for a future collaboration video with Karl and Jordan Bennett of Bennetts Customs.
That’s a killer idea I’d be all aboutbit
@@MakeItKustom totally doable
Always amazing to watch your work, plus I get to learn so much. Aaaaand, you do everything in the best of cheer. Stellar content! Thank you
I couldn't agree more. Great content, great attitude, and a gift for explaining the process.
@@leslieforster1774 😊👍
Thanks James ! Cheers!
@@MakeItKustom little simple advice take it or don't.....
Just take a picture and print that out instead of measuring drawing etc.... all you have to do is put a ruler in the picture to get the scale... just a time saver.... nice content
"A grill and a drinder." You are my spirit animal, sir.😂😂
Fabricator here from the CNC, 50 ton press, progressive stamping dies etc. Amazing to see you do this shade tree style, you are a true artist and enjoy watching your content!!! 😃
Thanks for doing such a good job explaining the steps to us beginners. Super cool video!
I do this press forming all day during the restoration of my 95 Mitsubishi Lancer. I use a mix of hard plywood and 8mm steel for dies/forms. And I can tell you the process takes ages to carry out but it is sooo rewarding when you see the shiney final product turning out like a new factory panel. 😎 great content Karl!! ps: and I only have a 12ton press so I have to move it around to 3-4 places on the positive die and apply the pressure in 2-3 steps.
Is it possible to form 16 gauge 304 stainless clamped to a wood pattern?
I want to make a big cookie sheet 3/4 deep with 1.25 inch radius corners, and a 5/16 inch curve between the base and sides, and 95 degrees between the base abs the sides.
Great tutorial ! Also award for Best Sparks in Camera Lens on RUclips.👍
Awesome video... I didn't think I would want to watch an hour video on beating a battery box, but so satisfying. Thanks
That was amazing! I never thought that would be possible without cutting out a load of different shaped pieces and welding them all together. Quite brilliant! And as you said, it wasn't the making of the battery base that was the main aim of the video, it was to demonstrate that with simple tools and techniques - and your insight - it is possible to make custom parts of all sorts. Just follow the principles shown here and volia - "I didn't buy it from China - I made it! Good innit. 🙂 Thanks from Jolly England. Bark Chip.
Thanks so much man you got it ! Its just amazing what can be done with a plate form
@@MakeItKustom Roger that, me old mate! I'm going to get on and remodel my face! Ha Ha!
I would've thought it was welded up also.
@@MakeItKustomSulfuric acid ? Yes... the vapors can also do that.
I had a 1980 Honda Civic hatch back where that happened over some years. It seems fairly common unless you make it out of stainless $$$.
Good work, Karl. Your freehand torch cutting was terrific. Such an interesting project. Thanks for sharing your skills with us.
When I was starting out as a pipe fitter's helper I worked for a pipe welder / fitter.
He kept his torch tip in his pocket and when the time came to cut a large pipe he put his tip in the torch.
He would then proceed to put a perfect bevel on the pipe while cutting to the finished length.
No grinding necessary, just file the land for the root past.
Some people are just extremely talented with a torch.
My dad always said a true mechanic gets the job done professionally with the tools at hand.
Whenever I see metal forming videos like this, I'm forced to think back to my old metalwork/woodworking teacher here in England. He was a well spoken, but brash man in his late 50's, and he had the air of someone who may have once been known as "Wing commander" about him. :)
Anyway, One sunny summers day he turned up to school in an absolutely stunning British racing green E type Jag coupe. Everyone was talking about it, and no one could work out how he would have been able to afford it on a teachers wage. It turned out that he'd bought it as a complete, but terminally rotten mess during the 1980's recession when prices were low (even for restored examples), and then spent 5 or 6 years rebuilding it to a showroom condition.
Replacement body parts were scarce AND expensive back then, so everything it needed had to be hand made by him. When he realised that a lot of us were really interested in the work he'd done, he brought in a crate containing several albums full of photos. It seems there wasn't much original Jag metal left in it ! The old shell was pretty much only used as a pattern to create replacement panels from. He even English wheeled a new roof panel because, as he said, the original had "too much rusty lacework around the top of the windscreen that needed replacing, so it would just be a neater job all round to make the whole thing from scratch. It was easier than messing about patching up the original all over the place".
He'd worked on some of the stuff at school near the end of the project. While we were busy doing stuff he'd be stood at one of the spare benches polishing things like carburettor body's, cam covers, or machining small alloy parts on the milling machine. Apparently he even brought in a roll of leather, and the old seat covers, then proceeded to sweet talk the young lady who taught needlework into making replacements for him. :D
It turned out that he was a qualified coachbuilder, and could have been earning a hell of a lot more money doing that, but it also tuned out that he really enjoyed teaching, and valued his happiness more than having an ever expanding bank balance (We thought he was mad because of that back then, but the older I get, the more I can relate to his point of view).
As a "Also" memory of the guy, I once asking him how he'd found the time and money to build that car, and I'll never forget his reply. He held up his left hand and said "You see a wedding ring on that finger boy? No? Well son, nothing in this world monopolises more of a mans time and money than having a wife. Being a bachelor is the only way a man can do what he wants, when he wants without interference. Yes, I was married once, but that didn't work out. We were both miserable, so chose to divorce before we ended up killed each other. There's some mistakes in life that you only need to make once. There IS a certain lady who I'm NOT married to now though, but I'm very firm on us having our own lives, and homes. We both like our own space, and she like's not having me under her feet all the time, messing up her place. While I'm equally happy not to be out wasting my time and money buying new sofas and soft furnishings every five minutes because the perfectly serviceable current ones don't go with the new wallpaper she's ordered........ It's a win win in my book. Just find yourself a woman like this my boy, and you'll have a lot less aggravation in your world". He'd probably have get fired and lynched for even THINKING that way these days, let alone recommending it as a way of life to a 14 year old boy !......... But it was a different (and more easy going) time back then. :D
Karl - you do such a great job teaching these techniques - it is truly a pleasure to watch. Hopefully in the not too distant future I will give this a shot. Great channel. Thanks for taking the time to share your skill.
I really appreciate all of your lessons and wisdom you share with all of us in RUclips land. It really shows that guys without a ton of tools can get stuff done. 👍
Fantastic ironwork! Many Greetings from Linz-Austria 🇦🇹😎👍🍺🏔✌️🐺 Europe!
You are the quintessential Canadian. You pronounce things differently than people from the states and your super nice and happy sounding!! You don't say "A" though and neither does zip ties and bias plys. Is that a regional thing? I heard a lot of Canadians in BC use it. As always, amazing work.
I love watching hammer form videos. Just so many possibilities. Those windows are amazing!
What a fantastic step by step display of this process! Great work!
Okay, I've said teacher in the past but now I'm thinking professor. You took us back to when you first learned about DIY forming. Great video, and by the way, most excellent music choices. At 70 I'm looking for my first gas axe. Thanks for the teachable moment and the prodding. T-Dub
Never thought I'd be excited about a battery box. Well done, I learned a bunch from this video.
Glad to hear it! Hammer forming is so versatile
Thank you so much for this video, for years I've looked at parts like this and just thought it'd be impossible to reproduce myself. I've never seen your channel before; I wasn't even searching for this, youtube just suggested it to me, but you've earned yourself a subscriber today. I'll definitely be using this knowledge in the future!
Wicked man glad to hear it! Welcome to the channel!
@@MakeItKustom Same here, found it while looking for something else. Love the detail in your instructions and explanations. I will definitely be using this information, though for far simpler projects!
You sir, are a true craftsman!! Very impressive and that is from a tool and die maker who bends metal for a living. Loved this video! Was wondering if you would rather not use WD40 for a lubricant, I know Harley forms fenders and gas tank pieces using liquid soap. It eliminates painting issues. Thank you for this video!
awesome video . Excellent teaching skills. and about the only person who doesn't blast the music at higher volume than the speech - so appreciated
It is a quite impressive battery box. I love how well the center depression turned out.
This was extremely well done, a fine example of complex forming made with a little ingenuity and hard work. Always superb content sir!
We need more videos like this. This is awesome! I was mind blown seeing how this can be all done by hand. From one tradesman to another, major respect!!!
just think of the suits of armour tailor made from middle ages. They did have buffers and grindstones, but that would have been more costly to rent than hiring a street waif.
@@markiobook8639 - i think about that stuff all the time! We simply stand on the shoulders of giants allowing us to reach higher until we become giants that allows the next generation to stand on our shoulders to reach higher. It is unfortunate that the tradespeople are a dying breed!
same@@bobdhitman
You make a hard thing look so easy but you do show every little detail? And I thank you so much
Look this guy is a master craftsman,show you a skill level beyond most . Great job.🎓
Karl, Man thank you so much for the great great content! It is always so timely and so encouraging to see. I've always been a person to build things myself after reading and researching what is involved. Channels like Make it Kustom really help... I've got some brackets to hammer form!
Awsome score on the windows and great shout out to them!
I’m pretty sure I’ve got a grill and a drinder 😂 Seriously, for those of us who weren’t lucky enough to grow up in this environment, or meet “the right people” along the way, your videos are so helpful. I know at some point I’m going to be able to put this to use on my project. Thanks again for sharing your skill and knowledge with us!
Mate thank you so so much, this officially is my favourite RUclips channel! I’ll get back into making some videos again some day
Beautiful !!!👏👏👏Thanks a lot for your videos !Congratulations from Australia!!
Karl, my guy! You are truly an artist with metal. That freehand torch cut was awesome. Really dig how you show and explain step by step procedures, your passion for it shines through. I’m a mechanic by trade and love to educate my customers in what, why, and how I am going to repair their vehicles. Most of them really appreciate it. Great video man, keep on keeping on.😎💯
Thanks David! Cheers!
Always amazed when I watch you work, Karl. You really take the time to show us some great and useful stuff. I do slightly different kind of metalwork, but I try to put just as much care an attention as you do. Thank you brother!
Your welcome man and thanks for watching and engaging 🙏👊
there's nothing like improvising to get what ya need done. love it.
VERY NICE VIDEO! It's great to see how you did and how we viewers can copy your methods. Greetings from Ohio.
This is AWESOME!! Thank you! Super awesome work as always
Appreciate the time and effort you put into making these videos 👍👍
You are a master of metal bro 😎… and a great teacher … imagine having a shop class in school 🏫 like this.
I’m back watching this upload again… some videos it’s good to watch them a few times.
🇦🇺🤜🏼🤛🏼🍀🍀🍀😎
Incredible craftsmanship and taking/walking us through the process! Inspiring stuff for anyone wanting to learn metal forming and fabrication! Great work Karl! Keep moving forward!
🙋🏼♂️Mano que trabalhei velho bastante trabalho Parabéns pelo seu trabalho muito bom🙌🏻👍🏻🇧🇷
If you want to keep this one from rusting out, something I used to make was cotton canvas soaked in baking soda, 3 layers, and let dry then the layers get sewed together. Lightly, or heavily, dust baking soda between layers first then carefully sew together so as not to lose the loose baking soda or shift it around between layers and sew a grid pattern to trap the baking soda between the layers. Once finished re wet with baking soda solution, let dry. Place on tray, place battery on that and Walla. Keeping the battery clean helps a lot too. I did this with all my hot rods back in the day. An old mechanic showed me how it was done.
or just coat in POR15
@@TheRoadhammer379 No! Por 15 doesn't neutralize battery acid. Whether or not it can tolerate battery acid isn't the issue. the battery tray will get scratched again and the acid will start destroying the tray again. You can paint it with POR but then use the cotton canvas soaked in baking soda to be sure the battery acid is neutralized when it comes in contact with it.. That was the whole point of my comment, was neutralizing the battery acid.
My lord it's refreshing to see young men still crafting, these lads keep this skills alive for another generation.
thanks again, working my way back through these older vids, 'cause, knowledge.
" True craftsman don't blame their tools "
Nice music 👍
One of the best how to video's I have ever seen.
I feel like we are so gifted with content creators on RUclips and the internet is better than schools really. Also I really appreciate the way you show people what they can do with some efforts if they make the decision to start and finish doing something. Again, amazing content.
Whith I noticed your first video and I stayed, Wow, who is this guy, this is real, he can do things so well, this is a phenomenon, and your videos are the same or better, you are a great person
You managed to make a simple over looked car part a piece of art
Didn't expect the cutting with the torch going so quick👀😎😎😎
Whoops you just answered my question ! Sixteen gauge……I’m impressed !!
I love watching a guy have fun with what he does. Great video, thanks.
... a very satisfying result, I'm sure. Metal shaping is an impressive skill. As a tool maker, I am impressed especially because I understand how expensive a production blanking and forming tool would cost for this. Thanks for posting!
The camera makes the flame look funky, but once you started cutting I could tell your torch skills are excellent.. hats off to you
master craftsman watching you cut the steel with a torch make it looks easy unless you've tried it then you don't see it years of practise right there great to see the old ways being carried on
You are one talented dude. And this was def. a more informative video than I expected. Thank you for providing this to the COMPENDIUM of edu on YT.
Awesome hammer forming video for the $1000 battery tray. 😊You’re an amazing craftsman.
Your hand is so steady with that torch!
I did a fair amount of fabrication working in the Auto body Repair trade for 45 years starting in the mid 60s, but this is nuts for a battery tray. i think if I had to make a run of them yes, but after watching all this work I need a nap, it is very enjoyable watching though, in the past i have spent time to make tools that i have used every day, some people wanted me to make there's too. like a spoon for moving body panels from a Chryslers leaf spring that i spent 3 hours polishing, of course on company time. i had one boss yelling i was making a pull plate for a shock tower, then the customers would come in and he would go we have to make special tools to fix their cars, i was giving him the finger behind the customers back. great work now make out 50 of them as they are the same on many cars.
It’s a good man that spends over $50 and countless hours to make an $18 part so that I can learn skills to make my projects better! I really appreciate you guys.
Such a great channel with such great content, I absolutly love it. You are a brilliant master inervator, problem solver, and talented craftsman. Thank you so much for sharing your God given talent with the rest of the world. I am blown away with not only what you do, but HOW you do it. Very much appreciated, on ya mate, thank you from Perth Western Australia.
Well done. Have a safe and nice day all. CHEERS from AUSTRALIA.
For some reason I was surprised you used a steel hammer. Wonderful job!
I had the skills and didnt even know it. Peening and welding brass and cast. I thoroughly enjoyed this vid. thanx
Well done. I worked for a company that fabricated there own tooling those guys could make anything back in the 70s
Fantastic tutorial mate 😃. The battery box turned out great. That press is a beauty, made short work of your press. Thanks for sharing.
The notches on the back are actually also there to mate up to the back of the battery itself to prevent sliding and hold it in place laterally. The battery has corresponding indents to those notches. That said, FANTASTIC Video! Thank You!!
Some cars depending on the level of equipment and/or whether it is a diesel or gasoline engine, can use batteries of different lengths, this allows the smaller ones to be centered or even placed against one of the sides, because in some cars the negative cable was made with the minimum length necessary to reach the post of the largest battery that fits in the tray, if a shorter battery is placed centered on the tray the cable no longer reaches the post, but by placing the battery against the side of the tray the post will be in the same place regardless of the length of the battery.
When a perfectionist decides to make a replacement for his car's battery mount.
I showed this to my brother who's in the business of vintage vehicle restoration and at first he could only shake his head. He told me he'd have just cleaned up the original, cut away the rusted part and welded a new piece in and called it a day. Not because he thinks that's a good way of working, just that no customer of his would be prepared to pay for his time to do what this video footage shows.
Nice to see that there are guys out there who don't believe in doing things by halves.
Every day is a school day and what a lovely teacher, I'm still learning at 61, keep going forever and thanks a million.
fantastic, you are one of my favourite educators. I maybe would've pressed the centre pan first, expecting it to pull in the sides. I'm 77 but your presentations inspire me to make something. Thank you
Joe Paton
Thanks Joe you are probably correct!
that feeling when you take apart a hammer form to reveal a pressed piece, it's pretty fantastic
Bravo.
As I was watching this, I was thinking of Fitzee and sure enough he shows up in the comments.
Custom by caveman!!
Love it.
I understand the physics but it's still looks like magic to me.
Simply...WOW.. A commonsense approach and a result that looks factory.
Congratulations. You are now not only a fabricator, but a tool & die maker!
You’re amazingly talented with fantastic enthusiasm, that part looked brilliant; I recon you underestimate you skill with the hammer alone.
I was blown away with the result.
While the $18 part is attractive financially, it denies people a learning and development opportunity which they can grow to even higher skills / more complex parts which you can’t buy… I think you are doing great job.
Потихоньку восстанавливаю свой GAZ-69A 1958 года. Машина уже стала семейной реликвией и была привезёна с територии крайнего севера, Охотского моря. Использую ваш опыт, для формовки панелей пола водителя и короба аккумулятора. Спасибо за контент👍
You are an artist with the angle grinder and gas torch! lovely hand skills.
YOU ARE A FINE SKILLED ARTIST, THANK YOU FOR POSTING, IT HELPS ME.
What a great job! Can’t believe you have that kind of skills in your age.
That was a lot of work, but amazing work. The final product looks factory stamped. Thank you for sharing.
I don't even own it but happy to see your success! Thanks for your efforts. Have a happy day!
This opened my eyes to a whole new sort of world.
you are teaching a masterclass in metalworking as well as a masterclass in teaching! such a valuable thing for all of us pros and beginners alike!?
Hay, My name is Outlaw JAC. This is Apr. 2022, and I was watching your video on building your Battery tray and you were commenting about the pocket in the center of the base and why it is there. But not really why it’s there.
Well I’ve built a couple myself for my old Dodge pickups. After building mine, I found out that it is there because, My first one I made I left it flat to save some time. About a year and a half after one winter the bottom rusted out worse than the original one. I then did some research on it. I found out that it is there so the bottom of the battery can breathe and the condensation can escape. And that is also why that hole is in it. Also by not cutting it out completely, it is still very strong just like putting the those weap dimples in for strength. 👍🏼
Really great video ! Thank you for sharing , refreshing to see a very knowledgable person share info and skills so humbly and presice.
Mind blowing dude, I never even considered this kind of thing to be possible in a normal home workshop.
Now I just need a hydraulic shop press. Dear Santa...
Badass! It's enjoyable to watch a craftsman work. And thank you for including the tips as well. Good stuff 👍
This man has to be the hardest working RUclipsr
Total craftsmanship Karl wicked with the torch
Wow, I watched this for the first time 1 year ago…and here I am again saying….Thank you for teaching us all wild skills
🇦🇺🤜🏼🤛🏼😎🍀