Good morning Wray, your flexible pattern system is just the ticket. I can't believe that this was not thought of alot earlier. I guess it takes that special person to look outside the box to see new ideas and concepts. Thanks for a great video. You take care.
I put my idea of the flexible shape pattern on the internet almost 20 years ago... This craft has a lot of traditional railroad tracks... Newbies most often look to tradional methods to learn or tool solutions.Traditionalists will dismiss anything new most often without even giving it a fair hearing. It is the same in all human activities.😁😁😁
@@proshaper Hi Wray, I would guess you know this, but, in his book "Professional Sheet Metal Fabrication", Ed Barr a McPherson College instructor, gives you credit for the method and does a nice job describing it.
@@proshaper What was the light bulb moment that led you to invent the flexible shape pattern technique. Did it hit you all at once or was it a long series of events that led to it?
Thank you for showing the entire work enstead of skipping through the slower stuff. But I've found that all those little things add up to teach all those fine steps that make life so much easier.
Working my way through your excellent catalogue of videos Wray. An hour is not too long when it is so rich with information. If it's late at night and I drop off to sleep I apologise, and promise to come back and finish the lesson next day!
Wray your dead on with the comparison of the other coach builders and they are not explaining the process as an instructor just a person doing something that we the future builders cannot get out of their video's. Keep up the great video's and explaining in detail all nuances of the panel build.
Wray the guys with a million views, lots of sparks, lots of drama, they provide entertainment. You provide an education. To me there is no comparison, it's like comparing a comic book to the Wall Street Journal. Well done!
There is no doubt that you are getting the point across beautifully. In watching these videos, it is now getting to the stage that I can just about guess what comes next. Great teaching. Compulsory and compelling viewing!
Sir, you are someone to look up to when growing up. Been watching your videos for a while now; enjoying of your ingenuity even more than your immense knowledge! Bravo! As soon as it gets safe to travel, I’ll try to engage in one of your courses. Thank you for sharing your knowledge.
Hi Wray, I took a two day class of yours I believe in in 2010. I was fortunate to be, for some reason, the only student! Thanks for this refresher course on the FSP and your invaluable shared knowledge, attention to detail and passion. Your method works! There is no other so called “expert” advice out there that even comes close to your videos precise and provable method to capture the DNA of a piece of metal. Your insightful breakdown of Area and Arrangement and your approach to focus on each throughout the forming process is genius. I’ve restored Porsches for years and can relate to your comments on hating rust and the benefits of skipping all the sandblasting, patching and planishing of old parts with making new ones. As you say, the proof is in the pudding...I’ll be sending you in a few weeks pictures of a completed body using your methods.
Wray, you are an amazing teacher and sharing your masterful skills in this environment is commendable. I can't understand why you don't have millions of views... I'm not a sheet metal guy but I am learning so much from watching your videos and the knowledge you share. You could write a book that with all that knowledge and it would be your legacy... Consider it.
Thanks for taking the time to do this tutorial. Making real parts in real time. Showing every step. Clarifying all the procedures. I hope viewers appreciate the knowledge and insights you are sharing. All for free! Thanks again wray.
Thank You, Wray. I enjoy listening to a Man that knows a lot about a particular skill. Your voice is calm and I listen to everything You say. You are an excellent teacher. Though, I don't have any plans to do any sheetmetal work. I design and fabricate my own clothes using flat cloth to form around compound curves. Also, My twin, Gemini Sister makes me stay in the kitchen, barefoot, to cook and do the dishes for Her. I can't even go to the garage! Thank You for Your videos, Wray. Miss Donna Chassis Honeyflow, submissive kitchen sissy :)
Great video Wray! Don't worry - the important people are watching and learning! Channels that focus on entertainment are everywhere and they do get millions of views. Channels that focus on craft take longer to build and audience but their value stays for all time.
Are there seriously people who expect to learn how to fabricate an E Type bonnet in half hour & just by watching? Keep Talkin' Wray, no edits please! Thank you for sharing.
I like your videos and philosophy of metal working. I usually work in steel. I tell the people that I teach you have to ask the metal to do what you want, don't force it. I have used flexible patterns since I heard about them. I have used 4 layers of masking tape by rubbing the first layer sticky side on my dusty up pants. I had never actually seen your method of flexible patterns. I like the translucent and reenforced packing tape. Jim Ford Highway 101 Rod and Custom.
Wray, thank you for showing every single minute of the panel development and not jump cutting to the finished piece. I am very happy to sit through hour long videos on panel shaping. Great choice of panel to duplicate also, the Jaguar hood has all the challenges. If you viewers get a chance to go to Massachusetts to take the class, do it. It is worth every penny. Every day goes from dawn to dark and there is not a minute you won’t be learning something. Bring a notebook and a camera, you will fill both.
I feel like the luckiest person in the world, I have to make a transmission tunnel with a reverse curve in it, even though it will be covered up, I want to make it as nice as I can. These videos help so much, I can't thank you enough.
I've watched every minute of your videos Wray!!! This is the kind of videos I like and I appreciate your efforts in teaching us how it's done and not editing it down to 10 minutes!!! You do great work and I'm learning a lot from watching you work your art!!! Keep Rocking it out!!!
Hello, thank you for your amazing content. It's like you say, in comparison with most other videos here on RUclips you really show how it's done!!! The lenght may scare some people away, but for me it's your strong point and absolutely worth watching for hours. ( wich I may do again for more than a few times!) Have it both ways, when you finish a project you could upload a 15-20min video with a catchy clickbait title to summarize and promote your hard work and extended playlist. I am sure one of your 7k+ fans is willing and capable to make something that stands out to the millions of people whom should see this! Cheers
Hi Wray, take all the time you want, as far as I am concerned the more time the better, I just love all your chat which all adds to the lesson, watching videos which are all high speed you learn nothing other than the chap in it is very good but he is not helping the Viewer, so again keep them coming as I will be watching them over and over till it all sinks in, Regards Eddie
Very nice of you to donate those to Wray. It's obvious from his previous vids that he really likes that brand of snips. They will have a great life going forward. Think of all the incredible panels and cars they will help create.
Worked in the aluminum industry for many years with the Hazelett Continuous Aluminum casting process. Did a lot of work in Venezuela in the 90's producing millions of pounds of AA3003 in various tempers and as I recall likely about 1/2 as thick for most of their sales. The main end use was for wrapping industrial piping systems, with large diameter piping, after insulation to protect the insulation. A somewhat similar alloy is AA3004 which is what beer can bodies are made from. It goes through an amazing drawing and ironing process to form the can, it is done in two steps; first a sallow dish is punched out of the sheet with vertical walls perhaps 1 1/2 " high and a flat bottom, the diameterr would be equal to the final can diameter. Second that shallow dish is fed to the drawing and ironing machine which uses a solid pin with the business end the shape of the finished can bottom. The OD of the pin will be the ID of the can. The cup is placed into the machine resting on a die that is thenegative version of the can bottom shape. The pin then pushes the cup down through dies that ddraw and iron the material into the shape of the can as the pin travels through it's stroke. The can bottom remains at the original sheet thickness, these days likely close to 0.012" thick, the can walls are thinner and thinner as you get to the top of the can ending up somewhere around 0.003" tk. You can see that the process asks a lot of the aluminum sheet. The lid and tabs are much stronger AA5XXX aloys. Just thought you might be interested in this rather amazing use of aluminum. Even one leaker in thousands of cans is a big issue. BTW the can does probably cost more than the beer. You might want to try some AA3004. Another application for 3003 was for oudore window blinds, the slats had foam cores with several zero radius bends to crimp together the front and back sheets and from a hook system that held the individual slats together so the blind could be raised and lowered. No cracking at the bends was allowed. I own an E-Type and have been interested in metal working as a hobby for years. Enjoy your talking, you are good at it, not everyone can do such a thing. Perhaps this is learned from your teaching. Tom G.
I watched all the videos in this series so far and really enjoy watching so keep them coming definitely motivated me to get back in the shop thanks for sharing
very good, i was not bad with steel in putting dents and twisted parts back in shape but your work is a world away from my days with a dollies and hammers
Having seen some hand formed car bodies in the "raw" I have wondered and marvelled at the techniques involved in their creation. As a layman, panel shaping seems to be the ultimate in fine craftsmanship and artistry. Your videos really shine a light on the processes and skills involved. I find your videos fascinating Thank you for taking the time impart your knowledge to the rest of us. I'm going to catch up on the rest of your postings. Cheers Russ P.s I have subscribed.
Just remember if you have some Sheet Metal that is .040" thick and 4' long and 2" wide. If you reduce the thickness to .020" it will be 96" long and 2" wide. Shrink the edges when you have a high crown and the reduction in thickness is very minor.
Thanks so much Wray. Your vids show me the that there’s hope and loads of fun to be found in metal bashing. I’ve had thoughts about making a new aluminum scuttle and wheel arches for our Lotus 7 replica and now I can hardly wait to get after it.
it took me ages to twig to the knowledge imparted in the first three mins of this video , this should be lesson two day one on every panel beating course lesson one is of course which end of the hammer to hold and which end to hit with.
For those that want to shorten the watching time without losing any information, just click on settings, cog icon bottom right, and select playback speed. I watch at 1.5 times so you can still understand everything but saves a 1/3rd of the time.
Thanks for vid. I don't know why this recommendation popped up, but somehow it did and I have aluminum hooded project cars! Lol... New Subsciber, guess I have some binge watching to do.
Thanks wray for all the effort you put in all your videos, ive been watching your videos since you were on william longyards channel, Such valuable information, keep em comming!!!!!!!!!
Anyone not interested in a 1 hour video sure as heck won't be able to work on a panel for days to make it as good as it can be. Besides.. just like working on a panel, you can "pause" the action and go back later. Lovin' the training you are delivering. Anyone who isn't enjoying this should just go watch some cute cat videos. Nothing wrong with cute cat videos.. just sayin'. As for views and likes, give it some time Wray. That louver press shouldn't deflect, given the size of the thing! :) The Lotus 9 is impressive.
Come on Wray, most people simply don't have the skills to absorb and then replicate what you do. And most watchers of you tube have less exclusive motors to work on so they are bound to share common ground with those who are less skilled? but more in tune with the "ordinary" car buyer. You just have to except the fact that your skills and feature video's are appreciated by the keener enthusiast and those who desire to achieve your skill level. Just remember, "small is beautiful". How the panel can turn from a bashed piece of tin into an e-type section is magical. Guess you'll get black listed by Donald for importing your sheet Aluminium! Thanks Wray.
I get amazing results from both absolute beginners and from those that have some experience at my classes. I would agree with you if I didn't see the work unfold before me from my students, using nothing more than my shrinking facilitators, mallets, and the English wheel. There are students that don't ask questions and they tend to stay off on the side doing what they think works. Most of the time their work is not the best and they are very difficult to give direction to. Can everyone learn to scrath- build a coach built car? Probably no. A lot of my students all they want to learn is how to make a accurate patch panel, weld it in and how to fix a dent. Which are all covered in my class, maybe I can inspire that person to reach higher. That is what I try to do. I know I will never be 100 percent successful in bringing everyone's skills to perfection, that can only come from internal drive. I teach a very easy to understand and accomplish method, I teach techniques not tools make results. Most people think tools are the most important ingredient.
some people have the knowledge to realize that when you look at parts already done they just dont fit the on the bonnet, look at the scoop on the bonnet. it touches at both ends but not at the middle, and having a flange turned on the scoop the shape is locked in. I guess a lot of off camera work will be done here
@@356porsche your comments are entertainment for my followers.😁😁😁, You just prove my point about dogmatic thinking which always holds back progress. Check out the 5 minute video I have of the work of one of my students. He had never wheeled a panel larger than 1.5 sq ft. before taking my class. He made a new aluminum boot lid and two fenders for a 1937 Riley using my flexible shape pattern system. The quality of his work was first rate. Nobody is saying your traditional method is wrong. There are always multiple excellent methods to achieve any human task.
Great videos please keep them coming. I do have a question for you. What crown is your english wheels? You say low crown but what is the actual crown of the most popular ones you use? Thank you
Love the channel, and the long in depth videos! I have a question about your big wheel (the yellow monster) what is the geometry of the upper wheel and the anvils? Seems like 12 inch diameter and 6 inch width? I am going to make a wheel and I love your large wheel. Also, what is the metal and hardening you suggest? stainless?
Hi wray dont get dishardened at the lower number of views it is better to have 500 people learn from you than 500k video hoppers that watch 5 minits of a video to see what it is!
At a body seminar, we learned that a lot of tap tap tap ads up and was better than a wack, wack. leastwise on a model "T" fender. Anyway, thank you for showing us how you do it.
Would it be fair to say that, if you had a flange on all sides of the work piece that you could use the kick Shrinker/stretcher on that flange to help or fine tune the arrangement as you did in one of the previous parts? And then cut the flange off afterward.
@@proshaper Thanks Wray. It was on the E-Type fender I noticed it. Watching this series again as I enjoy it so much. And pick up something new each time. Also you’re the only American to refer to an E-Type by its correct name not XKE 👍😂 Hope you’re keeping well!
@@shanedoyle1057 I have loved E-types since they were new. I bought a 1965 E-type for $500.00 in 1975. It needed a total restoration, my friend ended up breaking it up for parts after I sold it to him.
@@proshaper That’s tragic. They were very cheap at one time. Even I remember when they were 10-15k over here an aluminium bonnet for one costs nearly that much. You should watch the program called “Inside Jaguar making a million pound car” it was excellent! I’ll try find a link now.
I wish there were other metal work classes closer to boston that could teach me to shape metal. Do you guys ever do classes in other parts of the state?
I'm not from MA but I just googled it. Looks like Wray is only about 90 minutes away from Boston. That's too far? My father's daily commute to work when I was a kid was longer than that and he did it every day for over a decade.
Hi Wray. I have been in the automotive design and restoration business making panels for more years than I would like to remember. I was born in England in 1946 and at the age of 16 I started an apprenticeship training with Aston Martin for 5 Years. For the first few months I worked with other tradesman and was shown the principals and theories for making panels by hand, and learned the art of shaping aluminium. At that time we were making the DB series. When the time was right, I was placed in the section where the front guards were made. I worked there for a while, then moved to where the roof skins were made, then to where the lower valance panels were made, so all in all I was moved every 6/7 weeks to do these panels. In about 15 years working at Aston Martin I must have made hundreds of Ogee shaped panels as mentioned above. Please note that the return shape on the Aston Martin front guard is very similar to the return you are making on the Jaguar bonnet, a little different in height and width but the principle is the same.After 15 Years at Aston Martin, I decide to move on and with my qualifications. I found a good job in Belgium with a firm that worked on all classic cars, so I took the job and worked there for about 8 years. While working there I learnt new skills and new ways, and new theories by working on all sorts of classic cars. After that I decide to really make a move and emigrate to Sydney (Australia) and after a few months I found a good job working on all English marques. I worked there until I was 65 and then retired. So after watching all of your youtube videos making the Jaguar bonnet I decided to write this below : This so called ''Flexible Shape Pattern'' where does it come from? Who taught you that method of shaping? The reason I am asking is because it simply can not work, or give the operator anything conclusive to work with. No sign of the amount of stretching or shrinking needed. The way you wheel the panels with excessive pressure, (far too much for shaping metal) The width of your the top wheel, those wide lower anvils, All of those methods are a sure way to have a big problems when shaping panels and unnecessary time spent in making the panel. Unfortunately I regret to say that if you worked in a high standard work shop where you would have used all those methods, shown on your bonnet build, and the manner you approach that job including the Flexible Shape Pattern, you would have been dismissed immediately. It's hard for me to state this but unfortunately it's a fact!I have also taken the time to read most of your viewers comments, but one has to say that these people that are looking at your video's are not proper tradesmen and do not know any better. Therefore their thinking is that this is the correct way, when in reality it is definitely not.
Hi Elliot, I hope you understand that it's a big world and you will find that coachbuilders from Italy,, France, Germany, and America used methods that were different from what you learned in England. The Italians have made cars that are considered the best and the most valuable by collectors all over the world. I have 56 years experience in the collector car business/hobby. I started ar my grandfather's restoration shop when I was 12 working on restorations of J Duesenbergs, Packards, Rolls Royce, Bentley, Stutz, etc. From that early age I absorbed how cars are built. When I started learning Advanced coachbuilding skills in 1986 I was well prepared. I learned how other coachbuilders around the world shaped metal. I borrowed from coachbuilder techniques used around the world. I took what I thought made sense and added a few techniques of my own. I developed the flexible shape pattern system and have made 1000s of panels using it and have shipped the panels to customers all over the USA and Canada. I never got a complaint call saying my panels didn't fit, not one! I can have someone in Australia or from anywhere in the world make me a flexible shape pattern of any car's fender and mail me it in a priority international mail packet the correctly made pattern and paper outlines of the required profile gauges. When the packet is recieved (mail cost around$40.00 for international) I can make the fender ship it back to the source from where the flexible shape pattern and gauges came from and the fender will fit perfectly and be an excellent replacement in every way. Better than that the sender can send me a right side flexible shape pattern and gauges and I can make a perfect left side fender! But, I guess flexible shape patterns don't work.😁😁😁 Want to place a wager that I can't do what I say?
You seem to be working from the hardest part of the job, (the elaborate reversed curves of the inlet to the easiest, the comparatively flat parts up by the windshield. Is there a reason for that? For a beginner, it would be most likely to build confidence to work from easy to "how the hell do I do that?". (Coming from someone who failed handicrafts in primary school. :-)* )
Adam Savage from Mythbusters and Tested likes to do the same. He is not doing metalshaping but I think his philosophy still makes sense. He always tries to tackle the hardest stuff first. He claims it helps eliminate the burnout and mistakes in a project. As you get closer to the finish line the tasks ahead of you become easier. This helps build confidence and it also helps to motivate you to finish. Also a lot of Adam's projects are one day. As the work day progresses you become more tired and fatigued both physically and mentally. Leaving the easier stuff for later in the day helps eliminate mistakes. Of course Wray and Adam are not beginners so they have the skills to tackle the hardest stuff first if they want to. For the rest of us it may make a lot more sense to start with the easy stuff and work our way up to the harder stuff.
@@TheInsaneShecklador Good point about the progressive fatigue. I teach courses in IT, and I try to match the topics to the likelihood that the students will be awake and receptive. Late afternoon is not good for heavy stuff.
Good morning Wray, your flexible pattern system is just the ticket. I can't believe that this was not thought of alot earlier. I guess it takes that special person to look outside the box to see new ideas and concepts. Thanks for a great video. You take care.
I put my idea of the flexible shape pattern on the internet almost 20 years ago... This craft has a lot of traditional railroad tracks... Newbies most often look to tradional methods to learn or tool solutions.Traditionalists will dismiss anything new most often without even giving it a fair hearing. It is the same in all human activities.😁😁😁
@@proshaper Hi Wray, I would guess you know this, but, in his book "Professional Sheet Metal Fabrication", Ed Barr a McPherson College instructor, gives you credit for the method and does a nice job describing it.
@@jgerardmcmahon2032 I wasn't aware of that- awesome.😁😁😁 Wray
@@proshaper What was the light bulb moment that led you to invent the flexible shape pattern technique. Did it hit you all at once or was it a long series of events that led to it?
@@TheInsaneShecklador I got sick of taking panels in and out of arrangement to fit them to my copy bucks.
Your way is so much less work than making bucks you are a true genius developing this way to make panels
Thank you for showing the entire work enstead of skipping through the slower stuff. But I've found that all those little things add up to teach all those fine steps that make life so much easier.
Working my way through your excellent catalogue of videos Wray. An hour is not too long when it is so rich with information. If it's late at night and I drop off to sleep I apologise, and promise to come back and finish the lesson next day!
Wray your dead on with the comparison of the other coach builders and they are not explaining the process as an instructor just a person doing something that we the future builders cannot get out of their video's. Keep up the great video's and explaining in detail all nuances of the panel build.
Wray the guys with a million views, lots of sparks, lots of drama, they provide entertainment.
You provide an education. To me there is no comparison, it's like comparing a comic book to the Wall Street Journal. Well done!
There is no doubt that you are getting the point across beautifully. In watching these videos, it is now getting to the stage that I can just about guess what comes next. Great teaching. Compulsory and compelling viewing!
Thanks!
Sir, you are someone to look up to when growing up. Been watching your videos for a while now; enjoying of your ingenuity even more than your immense knowledge! Bravo!
As soon as it gets safe to travel, I’ll try to engage in one of your courses.
Thank you for sharing your knowledge.
Hi Wray, I took a two day class of yours I believe in in 2010. I was fortunate to be, for some reason, the only student! Thanks for this refresher course on the FSP and your invaluable shared knowledge, attention to detail and passion.
Your method works! There is no other so called “expert” advice out there that even comes close to your videos precise and provable method to capture the DNA of a piece of metal. Your insightful breakdown of Area and Arrangement and your approach to focus on each throughout the forming process is genius.
I’ve restored Porsches for years and can relate to your comments on hating rust and the benefits of skipping all the sandblasting, patching and planishing of old parts with making new ones.
As you say, the proof is in the pudding...I’ll be sending you in a few weeks pictures of a completed body using your methods.
Wray, you are an amazing teacher and sharing your masterful skills in this environment is commendable. I can't understand why you don't have millions of views... I'm not a sheet metal guy but I am learning so much from watching your videos and the knowledge you share. You could write a book that with all that knowledge and it would be your legacy... Consider it.
Thanks for taking the time to do this tutorial. Making real parts in real time. Showing every step. Clarifying all the procedures. I hope viewers appreciate the knowledge and insights you are sharing. All for free! Thanks again wray.
Thank You, Wray. I enjoy listening to a Man that knows a lot about a particular skill. Your voice is calm and I listen to everything You say. You are an excellent teacher. Though, I don't have any plans to do any sheetmetal work. I design and fabricate my own clothes using flat cloth to form around compound curves. Also, My twin, Gemini Sister makes me stay in the kitchen, barefoot, to cook and do the dishes for Her. I can't even go to the garage! Thank You for Your videos, Wray. Miss Donna Chassis Honeyflow, submissive kitchen sissy :)
Great video Wray! Don't worry - the important people are watching and learning! Channels that focus on entertainment are everywhere and they do get millions of views. Channels that focus on craft take longer to build and audience but their value stays for all time.
Are there seriously people who expect to learn how to fabricate an E Type bonnet in half hour & just by watching? Keep Talkin' Wray, no edits please! Thank you for sharing.
I like your videos and philosophy of metal working. I usually work in steel. I tell the people that I teach you have to ask the metal to do what you want, don't force it. I have used flexible patterns since I heard about them. I have used 4 layers of masking tape by rubbing the first layer sticky side on my dusty up pants. I had never actually seen your method of flexible patterns. I like the translucent and reenforced packing tape. Jim Ford Highway 101 Rod and Custom.
Wray, thank you for showing every single minute of the panel development and not jump cutting to the finished piece. I am very happy to sit through hour long videos on panel shaping. Great choice of panel to duplicate also, the Jaguar hood has all the challenges.
If you viewers get a chance to go to Massachusetts to take the class, do it. It is worth every penny. Every day goes from dawn to dark and there is not a minute you won’t be learning something. Bring a notebook and a camera, you will fill both.
I feel like the luckiest person in the world, I have to make a transmission tunnel with a reverse curve in it, even though it will be covered up, I want to make it as nice as I can. These videos help so much, I can't thank you enough.
I've watched every minute of your videos Wray!!! This is the kind of videos I like and I appreciate your efforts in teaching us how it's done and not editing it down to 10 minutes!!! You do great work and I'm learning a lot from watching you work your art!!!
Keep Rocking it out!!!
Thanks Pat!
Hello, thank you for your amazing content. It's like you say, in comparison with most other videos here on RUclips you really show how it's done!!!
The lenght may scare some people away, but for me it's your strong point and absolutely worth watching for hours. ( wich I may do again for more than a few times!)
Have it both ways, when you finish a project you could upload a 15-20min video with a catchy clickbait title to summarize and promote your hard work and extended playlist.
I am sure one of your 7k+ fans is willing and capable to make something that stands out to the millions of people whom should see this!
Cheers
Hi Wray, take all the time you want, as far as I am concerned the more time the better, I just love all your chat which all adds to the lesson, watching videos which are all high speed you learn nothing other than the chap in it is very good but he is not helping the Viewer, so again keep them coming as I will be watching them over and over till it all sinks in, Regards Eddie
I am glad you liked the Pro Snips. Keep up the great videos.
Thanks Randy! I will make good use of the shears. Of course I will modify them first to make them better.😁😁😁
Very nice of you to donate those to Wray. It's obvious from his previous vids that he really likes that brand of snips. They will have a great life going forward. Think of all the incredible panels and cars they will help create.
Worked in the aluminum industry for many years with the Hazelett Continuous Aluminum casting process. Did a lot of work in Venezuela in the 90's producing millions of pounds of AA3003 in various tempers and as I recall likely about 1/2 as thick for most of their sales. The main end use was for wrapping industrial piping systems, with large diameter piping, after insulation to protect the insulation. A somewhat similar alloy is AA3004 which is what beer can bodies are made from. It goes through an amazing drawing and ironing process to form the can, it is done in two steps; first a sallow dish is punched out of the sheet with vertical walls perhaps 1 1/2 " high and a flat bottom, the diameterr would be equal to the final can diameter. Second that shallow dish is fed to the drawing and ironing machine which uses a solid pin with the business end the shape of the finished can bottom. The OD of the pin will be the ID of the can. The cup is placed into the machine resting on a die that is thenegative version of the can bottom shape. The pin then pushes the cup down through dies that ddraw and iron the material into the shape of the can as the pin travels through it's stroke. The can bottom remains at the original sheet thickness, these days likely close to 0.012" thick, the can walls are thinner and thinner as you get to the top of the can ending up somewhere around 0.003" tk.
You can see that the process asks a lot of the aluminum sheet. The lid and tabs are much stronger AA5XXX aloys.
Just thought you might be interested in this rather amazing use of aluminum. Even one leaker in thousands of cans is a big issue. BTW the can does probably cost more than the beer. You might want to try some AA3004.
Another application for 3003 was for oudore window blinds, the slats had foam cores with several zero radius bends to crimp together the front and back sheets and from a hook system that held the individual slats together so the blind could be raised and lowered. No cracking at the bends was allowed.
I own an E-Type and have been interested in metal working as a hobby for years. Enjoy your talking, you are good at it, not everyone can do such a thing. Perhaps this is learned from your teaching.
Tom G.
Thanks Tom!
Hi Tom . Glad Wray didn't ask you how to build a Saturn V! You obviously had no interest at all in Aluminium Alloys!! Great stuff!
This channel is amazing.... and, keep talking... I appreciate you sharing your knowledge and expertise
Another great and helpful video Wray. So nice of you to keep them coming!!!
Thanks Wray, This is the most valuable video you have presented yet.
The info on the "Valley" has really helped me Ray! Great stuff!! Cheers, Doug
I watched all the videos in this series so far and really enjoy watching so keep them coming definitely motivated me to get back in the shop thanks for sharing
very good, i was not bad with steel in putting dents and twisted parts back in shape but your work is a world away from my days with a dollies and hammers
Excellent again Wray. Very informative. Keep em coming please !
Having seen some hand formed car bodies in the "raw" I have wondered and marvelled at the techniques involved in their creation. As a layman, panel shaping seems to be the ultimate in fine craftsmanship and artistry. Your videos really shine a light on the processes and skills involved.
I find your videos fascinating Thank you for taking the time impart your knowledge to the rest of us. I'm going to catch up on the rest of your postings.
Cheers Russ
P.s
I have subscribed.
Way to go Wray, get that Studebaker finished!!!
You are correct!😁😁😁 The Exner designed Studebaker is an amazing project. I need some more motivated students to push it forward.
Another question answered. You mentioned that all the stretching results in very little loss of panel thickness. Amazing
Just remember if you have some Sheet Metal that is .040" thick and 4' long and 2" wide. If you reduce the thickness to .020" it will be 96" long and 2" wide. Shrink the edges when you have a high crown and the reduction in thickness is very minor.
Thanks so much Wray. Your vids show me the that there’s hope and loads of fun to be found in metal bashing.
I’ve had thoughts about making a new aluminum scuttle and wheel arches for our Lotus 7 replica and now I can hardly wait to get after it.
it took me ages to twig to the knowledge imparted in the first three mins of this video ,
this should be lesson two day one on every panel beating course
lesson one is of course which end of the hammer to hold and which end to hit with.
Love you work, the way you have the plan and the process structured, great job, keep it up the subscribers will come, cheers
I was looking forward for the next episode... always very interesting, thank you so much!
For those that want to shorten the watching time without losing any information, just click on settings, cog icon bottom right, and select playback speed. I watch at 1.5 times so you can still understand everything but saves a 1/3rd of the time.
Thanks for vid. I don't know why this recommendation popped up, but somehow it did and I have aluminum hooded project cars! Lol... New Subsciber, guess I have some binge watching to do.
If an hour is too long to watch this wait until they try getting up and doing something!
Zeke has good taste in pens - I've been a fan of the Sakura brand for years, both pens & pencils
Thanks wray for all the effort you put in all your videos, ive been watching your videos since you were on william longyards channel, Such valuable information, keep em comming!!!!!!!!!
Anyone not interested in a 1 hour video sure as heck won't be able to work on a panel for days to make it as good as it can be.
Besides.. just like working on a panel, you can "pause" the action and go back later.
Lovin' the training you are delivering. Anyone who isn't enjoying this should just go watch some cute cat videos. Nothing wrong with cute cat videos.. just sayin'.
As for views and likes, give it some time Wray.
That louver press shouldn't deflect, given the size of the thing! :)
The Lotus 9 is impressive.
That is an interesting piece, thanks for showing and teaching!
So very cool another great episode thanks guys
Ground breaking method, so simple almost anyone could do it.
Come on Wray, most people simply don't have the skills to absorb and then replicate what you do. And most watchers of you tube have less exclusive motors to work on so they are bound to share common ground with those who are less skilled? but more in tune with the "ordinary" car buyer. You just have to except the fact that your skills and feature video's are appreciated by the keener enthusiast and those who desire to achieve your skill level. Just remember, "small is beautiful". How the panel can turn from a bashed piece of tin into an e-type section is magical. Guess you'll get black listed by Donald for importing your sheet Aluminium! Thanks Wray.
I get amazing results from both absolute beginners and from those that have some experience at my classes. I would agree with you if I didn't see the work unfold before me from my students, using nothing more than my shrinking facilitators, mallets, and the English wheel. There are students that don't ask questions and they tend to stay off on the side doing what they think works. Most of the time their work is not the best and they are very difficult to give direction to. Can everyone learn to scrath- build a coach built car? Probably no. A lot of my students all they want to learn is how to make a accurate patch panel, weld it in and how to fix a dent. Which are all covered in my class, maybe I can inspire that person to reach higher. That is what I try to do. I know I will never be 100 percent successful in bringing everyone's skills to perfection, that can only come from internal drive. I teach a very easy to understand and accomplish method, I teach techniques not tools make results. Most people think tools are the most important ingredient.
some people have the knowledge to realize that when you look at parts already done they just dont fit the on the bonnet, look at the scoop on the bonnet. it touches at both ends but not at the middle, and having a flange turned on the scoop the shape is locked in. I guess a lot of off camera work will be done here
@@356porsche 😁😁😁 stay tuned. It will be perfect, the flexible shape pattern insures that.
@@proshaper are you trying to convince me or yourself?
@@356porsche your comments are entertainment for my followers.😁😁😁, You just prove my point about dogmatic thinking which always holds back progress. Check out the 5 minute video I have of the work of one of my students. He had never wheeled a panel larger than 1.5 sq ft. before taking my class. He made a new aluminum boot lid and two fenders for a 1937 Riley using my flexible shape pattern system. The quality of his work was first rate.
Nobody is saying your traditional method is wrong. There are always multiple excellent methods to achieve any human task.
Great videos please keep them coming. I do have a question for you. What crown is your english wheels? You say low crown but what is the actual crown of the most popular ones you use? Thank you
Love the channel, and the long in depth videos! I have a question about your big wheel (the yellow monster) what is the geometry of the upper wheel and the anvils? Seems like 12 inch diameter and 6 inch width? I am going to make a wheel and I love your large wheel. Also, what is the metal and hardening you suggest? stainless?
great videos! just like building a body panel, you have to keep hammering to get a million views.
Hi wray dont get dishardened at the lower number of views it is better to have 500 people learn from you than 500k video hoppers that watch 5 minits of a video to see what it is!
At a body seminar, we learned that a lot of tap tap tap ads up and was better than a wack, wack. leastwise on a model "T" fender. Anyway, thank you for showing us how you do it.
A man can move a mountain one shovel at a time, but not all at once!!!
Keep Rocking it out!!!
Would it be fair to say that, if you had a flange on all sides of the work piece that you could use the kick Shrinker/stretcher on that flange to help or fine tune the arrangement as you did in one of the previous parts? And then cut the flange off afterward.
Hi Shane, Yes I use my kick shrinker on tipped flanges to fine tune their location.
@@proshaper Thanks Wray. It was on the E-Type fender I noticed it. Watching this series again as I enjoy it so much. And pick up something new each time. Also you’re the only American to refer to an E-Type by its correct name not XKE 👍😂
Hope you’re keeping well!
@@shanedoyle1057 I have loved E-types since they were new. I bought a 1965 E-type for $500.00 in 1975. It needed a total restoration, my friend ended up breaking it up for parts after I sold it to him.
@@proshaper That’s tragic. They were very cheap at one time. Even I remember when they were 10-15k over here an aluminium bonnet for one costs nearly that much. You should watch the program called “Inside Jaguar making a million pound car” it was excellent! I’ll try find a link now.
@@proshaper
ruclips.net/video/1fCRA_dBnhs/видео.html
It’s very interesting. A lot of manufacturers are going through their back catalogue these days.
Is there a video on how to make a flexable pattern?
Watch the earlier part of the E-type bonnet build series, I believe it is all there.
I wish there were other metal work classes closer to boston that could teach me to shape metal. Do you guys ever do classes in other parts of the state?
😁😁😁 ha I have students attend from all over the world.
I'm not from MA but I just googled it. Looks like Wray is only about 90 minutes away from Boston. That's too far? My father's daily commute to work when I was a kid was longer than that and he did it every day for over a decade.
@@TheInsaneShecklador my shop is about 50 miles from Boston. 😁😁😁
Hi Wray. I have been in the automotive design and restoration business making panels for more years than I would like to remember. I was born in England in 1946 and at the age of 16 I started an apprenticeship training with Aston Martin for 5 Years. For the first few months I worked with other tradesman and was shown the principals and theories for making panels by hand, and learned the art of shaping aluminium. At that time we were making the DB series. When the time was right, I was placed in the section where the front guards were made. I worked there for a while, then moved to where the roof skins were made, then to where the lower valance panels were made, so all in all I was moved every 6/7 weeks to do these panels. In about 15 years working at Aston Martin I must have made hundreds of Ogee shaped panels as mentioned above. Please note that the return shape on the Aston Martin front guard is very similar to the return you are making on the Jaguar bonnet, a little different in height and width but the principle is the same.After 15 Years at Aston Martin, I decide to move on and with my qualifications. I found a good job in Belgium with a firm that worked on all classic cars, so I took the job and worked there for about 8 years. While working there I learnt new skills and new ways, and new theories by working on all sorts of classic cars. After that I decide to really make a move and emigrate to Sydney (Australia) and after a few months I found a good job working on all English marques. I worked there until I was 65 and then retired. So after watching all of your youtube videos making the Jaguar bonnet I decided to write this below : This so called ''Flexible Shape Pattern'' where does it come from? Who taught you that method of shaping? The reason I am asking is because it simply can not work, or give the operator anything conclusive to work with. No sign of the amount of stretching or shrinking needed. The way you wheel the panels with excessive pressure, (far too much for shaping metal) The width of your the top wheel, those wide lower anvils, All of those methods are a sure way to have a big problems when shaping panels and unnecessary time spent in making the panel. Unfortunately I regret to say that if you worked in a high standard work shop where you would have used all those methods, shown on your bonnet build, and the manner you approach that job including the Flexible Shape Pattern, you would have been dismissed immediately. It's hard for me to state this but unfortunately it's a fact!I have also taken the time to read most of your viewers comments, but one has to say that these people that are looking at your video's are not proper tradesmen and do not know any better. Therefore their thinking is that this is the correct way, when in reality it is definitely not.
Hi Elliot, I hope you understand that it's a big world and you will find that coachbuilders from Italy,, France, Germany, and America used methods that were different from what you learned in England.
The Italians have made cars that are considered the best and the most valuable by collectors all over the world. I have 56 years experience in the collector car business/hobby. I started ar my grandfather's restoration shop when I was 12 working on restorations of J Duesenbergs, Packards, Rolls Royce, Bentley, Stutz, etc. From that early age I absorbed how cars are built. When I started learning Advanced coachbuilding skills in 1986 I was well prepared. I learned how other coachbuilders around the world shaped metal. I borrowed from coachbuilder techniques used around the world. I took what I thought made sense and added a few techniques of my own. I developed the flexible shape pattern system and have made 1000s of panels using it and have shipped the panels to customers all over the USA and Canada. I never got a complaint call saying my panels didn't fit, not one!
I can have someone in Australia or from anywhere in the world make me a flexible shape pattern of any car's fender and mail me it in a priority international mail packet the correctly made pattern and paper outlines of the required profile gauges. When the packet is recieved (mail cost around$40.00 for international) I can make the fender ship it back to the source from where the flexible shape pattern and gauges came from and the fender will fit perfectly and be an excellent replacement in every way. Better than that the sender can send me a right side flexible shape pattern and gauges and I can make a perfect left side fender! But, I guess flexible shape patterns don't work.😁😁😁
Want to place a wager that I can't do what I say?
You seem to be working from the hardest part of the job, (the elaborate reversed curves of the inlet to the easiest, the comparatively flat parts up by the windshield. Is there a reason for that? For a beginner, it would be most likely to build confidence to work from easy to "how the hell do I do that?". (Coming from someone who failed handicrafts in primary school. :-)* )
The nose sections were the hardest part then I went to the center and now the sides. No real reason.😁😁😁
Adam Savage from Mythbusters and Tested likes to do the same. He is not doing metalshaping but I think his philosophy still makes sense. He always tries to tackle the hardest stuff first. He claims it helps eliminate the burnout and mistakes in a project. As you get closer to the finish line the tasks ahead of you become easier. This helps build confidence and it also helps to motivate you to finish. Also a lot of Adam's projects are one day. As the work day progresses you become more tired and fatigued both physically and mentally. Leaving the easier stuff for later in the day helps eliminate mistakes.
Of course Wray and Adam are not beginners so they have the skills to tackle the hardest stuff first if they want to. For the rest of us it may make a lot more sense to start with the easy stuff and work our way up to the harder stuff.
@@TheInsaneShecklador Good point about the progressive fatigue. I teach courses in IT, and I try to match the topics to the likelihood that the students will be awake and receptive. Late afternoon is not good for heavy stuff.