HOW-TO Make CURVED FLANGES on SHEET METAL With HAND TOOLS Installing JAGUAR Gas Cap PLYMOUTH Fender
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- Опубликовано: 7 авг 2023
- On this episode of Make It Kustom, I install a 1980s Jaguar gas cap in a 1948 Plymouth fender using simple tools to stretch the flange of the Plymouth sheet metal over the Jaguar gas cap structure. Follow along to learn how to make your own sheet metal flanging tool.
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A lot of people would scrap the video when the holes started cracking, but thats half of the educational value of watching you work. Thanks for sharing your Skills Karl 👍🇬🇧
Made mine out of a piece of 3/4 round stock, goes around the bend like no ones business.
Showing these old tricks is a big help to many, well done Carl
That's a really good idea. I was thinking of a slimmer tool so it wouldn't bite into the corners is hard, but a round tool would avoid that entirely
I would say to use 3/16 bar stock, so it took a smaller bite, also, we used to use a tool that was a round rod for a handle, with two rollers bolted on one side. You slipped it on the edge and just roll it back and forth to flange the edge. What I had was 1/4 inch flanges, but a thicker wheel would give a wider flange
I'm #42 like... This video is showing us what not to do which I like. No point in criticizing as after a long day of trying to get somewhere kind of narrows your thinking.
Came to say the same thing. Easier on the hands too. Also a bit longer for leverage.
I really appreciate the editing of the sound. Like the grinding and pounding turned down, it makes for an enjoyable viewing experience ❤
Que trampo top❤Qual o nome dessa tampa de tanque?
Thanks for noticing! Cheers
Brilliant as usual. 😅
Hey, wouldn't it have been better to cut a piece out of another piece of sheet metal 1/2 to 3/4 inches thick, then weld it in and grind it smooth ?? Anywhere I love your content
seeing thart@@MakeItKustom seeing that it has to be welded, , id cut the flange in about 6 places, makes for easier bending, & wont split. & yes, id grill holes first. not as many.
Thanks for the video Karl! My dad was a metal man from way back (1950`s) and I learned a lot from him. He used to watch me repair dents and always required metal finishing whenever there was access to the backside of the panel. He taught me to always use heat whenever I needed to re-establish a flange. I think that more heat earlier in the process might have avoided the work hardening that caused the cracking. I would also say, an 0 or a number 1 tip on your torch would have allowed for better heat control. But in the end, you made it work and look great, so Cheers to you for a super fly modification.
Karl is a born teacher. This dude’s knowledge, skill and patience is fantastic.
Karl, If you’re ever in the market for a middle aged inexperienced intern, sign me up!!
YOU are the Bob Ross of metal shaving
You are a premium educator. I especially like that you make mistakes (drilling holes) but can show us how to correct and move on. Always inspiring.
This lad is up there with the best of them if not one of the best.
Karl, you’re like the Bob Ross of metal working.
Whoa there partner where are you trying to go with that what you trying to say
@@chauvinemmons Why the surprise? Bob Ross was a master of his craft and both relaxing and enjoyable to watch.
My dad built tools for a special purpose, like you just did sometimes for just a single job never to be used again. I learned a lot from him and I'm still learning from guys like you. Thanks Karl!
It takes time as you said.
I once asked my grandad how they did the work back in the day without all the tools we have today. He was born in 1908. His answer was " We had the best tool there is... time".
the drain is for rainwater, as the cap sits flat ( horizontal ) on the jag, and the well would fill with water. great vid as always
I'm #15 like... He was doing this for his friend after all.
The fact you try something new on camera and then post it with no editing (aside from sound and some FF ) is awesome. I know that feeling like the plans not working out and you then adapt and tweak and just don’t quit and it always seems to work out.
Great job on the video and sound management !
Very interesting. Certainly reinforces how Fitzee would approach this modification. 👍👍😎👍👍
Like so many of us older farts have come to realize, life is too short to make all the mistakes yourself. Thank You for this insight. JD
You are truly a sheet metal doctor
I wish I could drive my ‘82 Vanagon Westy up there and build a custom headliner pan
Not taking anything away from your job, very interesting technique. I can't help but think how Fitzee probably would have done it. Take a 3" wide strip of sheet metal and bend it into your oval that fits your flange. Cut the oval into your fender and tack weld it all in. Then cut it and sand it to fit the curve of the fender. No worries about creating a flat spot by bending in the flange. I think he would have had it done in 20 minutes.
Nothing happens in 20 minutes.
Yeah, absolutely I think it would’ve been much quicker to do it that way
@@seanfitzgerald4052yeah, +100… nothing of any complexity happens in 20 minutes. I know the OP is probably exaggerating a bit to make a point, but I’m going to guess that some of the complexity here wasn’t anticipated until he really got into it, which is a thing, no matter how experienced you are. Been there….
@@rmTheWalrus 😉👍
Diligence and patience and sense enough to back off and think it thru, nice work.
Takes a lot of guts to do something like this on camera even with the skill this fellow has. That customer must've really wanted that gas cap. Anyway, good job and thanks for keeping it real by showing the trial and error steps. I respect that. Good work.
Hey Karl
When you started to drill those GIANT holes I thought you had lost your mind !
I would have thought 1/8" holes would have been better.
Also I thought you would have used a brazing tip to heat the metal rather than the giant cutting tip.
But we do not all think alike !
Work Safe, Be Well
Enjoy Life
Hey Karl, great educational video and it couldn’t have come at a better time. I’ve just started the metal work on my first project, a 72 Dodge Demon. I plan on using the fuel door from a 69 Charger. I now know how I’m going to do it. I use you’re videos as an educational resource and I’m quite pleased with the results I’m achieving. Thanks!
Did the Challengers have a similar fuel cap?
That’s great Alan! Thanks very much. I am glad to hear this was well timed for your demon Project!
@@johnkranyics281 Not sure what the Challengers had.
Lets go!!! Love this Karl!
I enjoyed the working out how your going to make it happen and the corrections made along the way. Makes me want to get out and try that myself
U pulled the rabbit out again. Love your segments on home made tools.
you are a fine upstanding young Gentleman making it very easy to learn from you because of your friendly, mild mannered aura. May life bless and reward you.
When it comes to art you must move slowly and gradually chip away until you find the sculpture underneath. Thank you for your wisdom
One thing about metal, there's so much to learn. Great video's.👍
I love that amazing planishing hammer, it looks almost neolithic like the horns of some ancient mammal
I would love to buy one,but i know i do not have the skill to use it,and would merely spend my workshop time polishing it and oiling it !!!
I love watching you shaping and forming and teasing the metal to shape
Its like being a chil again and watching my father create things
A guy showed me this trick a number of years ago. Since that day I've showed as many people this trick as will listen
Nice work just the same, you brought us to School as well as yourself, "Every Day is a learning Day"-Gene Winfield
Thanks! Karl ! This one was a great Video as always 👍
It takes a lot of courage and self-confidence to dive into a project using new techniques on materials where you can’t go buy a replacement if you make a mistake. Kind of like a surgeon that is deep into an operation that can’t just go home when things aren’t going well and start over tomorrow. You soldier through and achieve a professional result. It is a joy to watch.
Once you get into your mind that you can often make what you need, it really opens up possibilities. I've made stuff that I've only used once but still well worth the time.
thanks, always nice to have helping hands who understand what your doing and understand what is needed next
A couple months ago one of your videos inspired me to bang on some metal. To make a parts washing basin, I cut about 6" off the bottom of a 5 gal steel can and made the exact same flange tool to turn over the cut edge then hammer and dolly it flat. Works great. Thanks for the inspiration. You rock!
I love these videos that show off a simple tool and technique that us guys with no room for fancy tools can use. Another first class low tech lesson video. THANKS !
Loved the heating part Karl, you'll become a blacksmith one day bud! Narrower piece of steel with rounded corners might have worked better on the tight radius? Hammer it out on your anvil.....
Hey Karl. Just a thought I've had over a couple of your videos. When you're planishing by hand, the fast motion takes away the sound of the hammering. It would be good to occasionally hear your hammering to get the gist of when you are on or off dolly. I think that is part of getting the feel of what you are doing.
Thanks for the feedback I appreciate it!
You’re a brave man. I’d have had to practice on a dozen junk fenders before I attempted it on the target fender. Thanks for taking us along
Fantástico! You Are , ( My Personal Opinion) The best in RUclips.
I did the exact same years ago. With the jag fuel cap on a 41 pymouth. I started from scratch. Much easier and very accurate. The hole on the side is the vent. There should b a nipple on the neck. You did not put a drain at the lowest part of the unit. You need one for fuel spilled due to over filling. I have pictures of mine. The cage should have 2 holes, 1 vent,1 drain.
Remember everytime you French in on a top or side surface a drain hole must be incorporated into your design at the lowest point. Automotive Coatings are not designed for submerged applications. They will fail.
Hard work makes the dream work
Wow, 4 hours for such a beautiful metal work.. Impressive..!!
The ability to recover from things starting to go wrong.... that's what it's about. And that video right there is was an example of how a Jedi recovers from it.
Great finished product. You are a Master with a hammer. That fender looks great again !!!
Hey Karl love you videos and the way you explain the techniques. I am in uk and use gas torches I have a device called an economiser which is basically a valve with a hook and the weight of the torch shuts the valve so flame goes out. To relight there is a pilot light so just lift torch and use pilot light to relight it. Safer than leaving torch alight on a stand and also saves gas. No idea if they are available in your country but here you can get them for oxypropane or oxyacetylene here.
Best real DiY car shop channel...
forgot to say the music is a perfect backdrop ! great touch
pretty cool alternative to stretching
A rose bud tip was what was used back in the day, some of these electric heat guns will give you more control over the heat transfer to metal. Great video 👍
Thank you for sharing the struggles man it’s so much more relatable
I now know what a tool I found in my box is for. It was a round stock piece with a few cuts like yours, all at different angles. Glad I didn't get rid of it. Great work as always.
Awesome job,Carl you are great
Air grinder? Nice. I need one of those. I have a gagillion spot welds on a 1950s Willys floor pan and that will make my like much easier. Excellent video. I can put that flange tool to use immediately on my project
Perhaps cutting the oval to size and welding a half-inch strip of steel perpendicular to the inside of the fender would have been easier. Beautiful when finished, the gas cap looks really nice.
That mini custom in the background is Rad!!!
Great custom work, thanks for showing how you do it,1 step at a time good,bad or indifferent, it comes out with work.
Great video Karl and another great tip for making the tool. The learning experience is amazing and for you trying the process for the first time and then telling everyone what you felt was a mistake you made, and don’t do it the way you did it so we don’t make the same mistake. That shows a mark of a good teacher and you caring about the ppl who watch your videos
Great job! You showed that even the experienced can learn.
I always learn from you Kevin. One thing I like the most is you admit when you make a mistake and tell your audience what happened and you give the don't do what I did but give the audience sound advice on what to do. This says a lot about your character to help people learn. You are awesome 👌
Thanks Benny I appreciate you! 👊👊👊
Excellent camera work and editing. Thank you for the video
Great job , great video , great music !!!!!😊
Great to see from start to finish. Even with mistakes. Keep up the learning.
Cheers O.
I just love people who can make stuff with their proper hands!!!!❤
Looks freakin sweet!!! It’s always more work than we think it’ll be but if everyone could do it it wouldn’t be special!
The sign of a craftsmen Is being able to correct mistakes! Well done.
I enjoy that your honest with us, showing the process, not "mistakes" but learning curve. Thanks so much !!
If you've never done that before, it came out pretty good regardless.
Even Karl figured out another way it would have been less work to accomplish, but if you don't try you'll never know. Like he said, learn from your mistakes for the next one. Thanks Karl 👍
There's some learning with new tools but you always find a way. I appreciate that.
Love it!! Thanks Gents
Yet another great vid Karl the hole in the housing is to let the rain water out to stop rusting as depending on which model some were mounted on the top of the a lot of cars so it fills up in britain we get lots of rain 🤣 also in the past I have use a set of mole grips to do the same sort of thing and because they clamp to the sheet you can get a very tight radius by gently tapping the top as you bend they come in a lot of different widths and angles and are very cheap
Enjoy watching you work the metal as you sure know what your doing. As I was a welder myself, now retired.Nice job young man.
Wish you were our shop teacher in metals class, back in the early70s. You have the gift.
I wonder how round bar would work in certain areas hmmm
Learned this from Ron Covell in the early 2000's ... great instructional ...
I used this exact gas filler door on my Dad's 32. I wish this video was out back when I did it! Great tips, thanks!
It's only a mistake if you or somebody else doesn't learn from it. Great work.
When you are a sheet metal fabricator and own a welder every problem looks bendable and weldable. 1. that gas cap looks cool 2. why not save time and make it look good by bending the receiver to match the underside of the gas cap area. add nutplates then matchdrill the screw holes and proseal it in place so it won't leak. The gas cap "look" would then be surrounded by say 6 or 8 fasteners and it would have a cool "aircraft/vehicle" one off kind of look. I also like pop rivets and anything that shouldn't look like it belongs on what ordinarily should be expected. I think your show is amazing and I look forward to more insights on your perspective of how the world can be made better!
Lots of innuendoes in this one, massaging your flange… 🤔🧐😂
Nice work 👍👍👍
as always, it was a fantastic learning experience! Thank you Karl.
Way COOOOOL! ANOTHER TOOL TO ADD TO MY ARSENAL.
The Bob Ross of metal craft.
It’s cool watching you work through the problem-solving aspect of this project. Thanks for keeping it real and not editing all that out.
Great video Karl, when you don't have the tools it takes a lot of imagineering to get the results your looking for.
I love that you always show the good and bad of doing metal work. Thank you Karl.
Annealing works well, remember how well Brent's car was annealed and how easy it worked back into shape.
outstanding skills… could watch for hours
I built an adjustable depth one from a 1/2" bolt 6" long. Made a deep cut across the threaded end slightly off centre. This gave me a wide and narrow anvil for working different circumferences by turning the bolt 180º. Next I slipped on some 1/2" ID rubber hose to protect my hand, then wound on a nylock nut. This can be repositioned to make different depths of slot. Use a round cap screw [allen head] to be even kinder to your hand - you will likely make 1000s of tiny bends with it over the years. Cheers from NZ.
Nice work sir. Thank you.
Hey Karl , thanks for another great class. I have short crescent adjustable wrench I use for flanging . It is about 5/16 inch wide and works great in tight spots.I also have a homemade wrench like yours, but mine is bent into right angle .works great. Please keep these videos coming!
Nicely done work, turned out a lot more work which was expected..a sweet custom gas cap choice.
That looked like a job I certainly wouldn’t want to attempt myself ! I know why your buddy bought it over to you Carl nice job dude it looks amazing 👍
Karl! You need to buy a number one tip for your torch! better heat control! Great video!
Hahha ya I have them was just lazy Larry 😂
You are a PRO! Fantastic job👏👏😊
Great job ,can't wait to see it all covered. 😊😊
That was cool.
I reckon I'd have used a ~2 inch strip of steel formed within the filler cap's 'bucket' so that the oval shape was set and then let that into the fender, welded it out for a sharp corner and and buzzed off the excess steel above the panel.
Neat little tool. I made a very similar (just significantly smaller) one to open up those older mechanical gauges. Had a few that worked well, but needles were too fainted to see easily. It's sort of the opposite task with those since you have to de-flage their shiny "beauty rings" to get inside, but the idea worked well.
If you do need to open one up, wrap the beauty ring with few layers of masking tape (so you won't scratch or stretch the outside), then un-flange the beauty ring on the back side and remove it together with the glass. From there you can touch up the needle, or remove needle and face all together for servicing of the gauge mechanism. In some cases you'll need to take couple nuts off the back of the gauge and the entire assembly can be removed from the housing. To re-assemble, put everything together and gently fold the beauty ring flange back down/in. Work on a piece of leather (piece of old boot even) to keep from scratching up the front of that beauty ring.
Nice job. Beautiful work. Hindsight being 20/20, I think I would have cut the hole out slightly oversized. Then welded on a strip of metal so that the strip extended slightly above and the required distance below the fender, making a T all the way around the hole . Then ground the new strip flush to the top of the fender and plug welded in the Jag piece. No stretching the metal. The flange tool would be handy for final fitment.
I'm on night shift, fell asleep when the music started. Nice work though. I'm learning lots
Thanks for sharing the mistake parts, it helps us who aren’t metal gods to better understand what happens when you think you got it figured out