Proshaper Class Bugatti Build Follow up.
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Proshaper Class Bugatti Build Follow up.
In a few minutes, Scott from Texas will be loading his Bugatti Atlantic project in his trailer. Here is the follow-up video.
This is what Scott accomplished at the ProShaper coachbuilding class. He attended the 13 days class plus 4 additional days.
I have to say this is quite the accomplishment. The quality of the panel work is first class and he did it in a timely manner.
Email: Wray@Proshaper.com
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English Wheeling Aluminum Panels - 1979 Firebird part 3
English Wheeling Aluminum Panels - 1979 Firebird part 3
This is Tim's final video for this year as he is taking everything back with him to Australia. We enjoyed having him here and hope to see him again next year!
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Tail section of a 3 Wheel Cycle Car
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Tail section of a 3 Wheel Cycle Car
Alvro and AJ did great on their first panels. First time they ever used an English wheel.
Sorry for the delay in our videos, we have been bombarded with work and it just keeps coming.
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44
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Tig welding aluminum
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Tig welding aluminum
This is a quick video Wray did with his student who wanted to learn TIG welding. He only had a few hours previously with a TIG welder and he definitely improved his skills. Does it pass the stress test?
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105
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Porsche 550 Dash Build (Part 10) Making this part
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Porsche 550 Dash Build (Part 10) Making this part
Now that we have 3 panels made for the dash, we are tackling one of the last parts. We start off how we always do, taking the flexible shape pattern off the panel, cutting a blank out of aluminum sheet, then using the F.S.P. wheel out the area value of the panel. Hope you're all happy now that we're back!
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30
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B-29 Turret Resurrection
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B-29 Turret Resurrection
Van from Quest Masters Museum http://questmasters.us/ came to the shop for our latest 4-day coachbuilding class. What he brought in was incredible and a complete mess. Over the last 4 days he beat the turret into submission, then used the English wheel to smooth it all out. By the last day it looked as if he brought in a whole new piece!
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Metalshaping: Making a reverse curve on a wireform
How you can make a super complex reverse curve panel when using a wireform.
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Metal Shaping Flexible Shape Pattern Power
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Metal Shaping Flexible Shape Pattern Power
This episode features an extended learning student from Canada named Ian. Ian has a 1959 MGA Twin Can and he wanted to learn how to make a pair of fenders. He has an English Wheel at home but he wasn't very proficient with it which is why he came to ProShaper. Wray had him make a flexible shape pattern of the fender he already has and then off he went. You can see in the video how well his fender (or half fender) came out!
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28
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Alfa GTV Hood Shrinking Disc Follow Up
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Alfa GTV Hood Shrinking Disc Follow Up
Email: Wray@Proshaper.com
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24
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Metal Shaping Buck Comparisons
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Metal Shaping Buck Comparisons
In this video Wray talks with Ken a student of ours discussing the finer points of the Wire form vs. Wood Buck vs. a Flexible Shape Pattern. The rule is, if you have the panel available then the Flexible Shape Pattern is the way to go. If you're recreating the buck from a picture then choose a wire form. It's cheaper to build, you can always change the flow by cutting the wire, fixing it and re-welding it back in.
Now when fitting a panel to the buck you'll notice you can see how it fits whereas on a wood buck it's difficult to clamp a panel to it and if you do, it's hard to see.
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Shrinking Disc Magic #shorts
#shorts
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Here is a short of our latest video showing the magic of the shrinking disc!
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22
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Shrinking Disc Magic
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Shrinking Disc Magic
Hey all, sorry for the delay in our videos. The last 5 weeks or so we've had 3 classes and several students stay for our 130 Hour shop special. During this class however we have a student who brought in an Alfa GTV hood that has a lot of high and low spots. Instead of chasing them with a slapper and dolly Wray took out the shrinking disc to show the magic behind it.
As you can see he probably used it for about 3 minutes and took out 95% of the highs and lows. There is still a few spots we need to chase but this video is just to show how in a short amount of time you can bring back a panel to it's original shape.
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22
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Super complicated metal shaping: Porsche 550 Dash (Part 9)
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Super complicated metal shaping: Porsche 550 Dash (Part 9)
We're back on the Porsche 550 Dash! Last episode Wray tac welded the top of the dash together and now wants to start making the lower portion of the dash. Of course we start where we always do and that's having made a flexible shape pattern and gauges.
With this information we cut out a sheet metal blank, larger than the F.S.P. to accommodate for the flanges and allowing for a little "cheat room". Now this part of the Porsche dash is rather tricky as it has all kinds of curves, a few bends and several flanges.
Wray starts by stretching the edges with a beater bag and metal shaping mallet. Then planishing it out on the English wheel, he also starts to arrange the panel. To add the curve on the side he uses a shrinker/stretcher and the gauge as to not over do it. We end up in a great spot at the end, however the tipped edge towards the bottom of the dash may need to be re-tipped as the line slightly moved. We hope you enjoy it, Metal is Clay and have a good day!
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Metalshaping: 550 Porsche Dash Subassembly
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Metalshaping: 550 Porsche Dash Subassembly
We are at the point of welding. Wray instructs us on how he ensures the panels are clamped together in the correct spot. If you meet the two panels, and they're off just a little it can have a major impact on the end.
He adjusts the dash and corrected my (Mark) radius zone on the flexible shape pattern and added a few weld lines and now how tac welds the panels together using the Everlast welder. I try a few different lenses to see which one worked best and have decided to try a neutral density filter so hopefully our next welding video will show the weld puddle better.
Also thank you all for subscribing to Alison's channel, we greatly appreciate all your support!
Email: Wray@Proshaper.com
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Metal Shaping sometimes equals chess
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Metal Shaping sometimes equals chess
Porsche 550 Dash (Part 7)
First off, we ask that you please subscribe to Wrays amazing daughter Alison who's voice is out of this world. Click the link below if you could, please and thank you!
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Boring Alert!
This video has a lot of everything in it but is very tedious. You'll see that when we change the arrangement on one end, it changes the arrangement on the other side so it is very much like a chess game.
Wray mostly focuses on the area around the instrument panel to make sure the flow is correct and identical to the panel from Bruce. Using the English Wheel we planish out the hammer blows and by the end Wray decided that the next video will be welding the two panels together to stiffen up the middle. Once we do that, arranging the panel won't be so much of an issue.
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Metal Shaping a Porsche 550 Dash (Part 6): Perfecting Details
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Metal Shaping a Porsche 550 Dash (Part 6): Perfecting Details
In this episode of the Porsche 550 Dash Wray is perfecting the details. Wray starts by heat shrinking some high spots in the panel and by doing so he is able to add the valley on either side of the dash. Using the caulking tool, Wray moves the valley over to the correct location and the using the shrinker/stretcher kick stretches to add more are to the panel. Lots of tweaks in this video, Wray always said the last 10% of the job is 90% of the work.
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Metal Shaping a Porsche 550 dash (Part 5)
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Metal Shaping a Porsche 550 dash (Part 5)
Back on the Porsche 550 Dash. In this video Wray is refining the dash with the English Wheel, a delrin tool and a metal shaping mallet. He uses the flexible shape pattern to show any deficiencies that need more attention and locates 5 spots to work on.
Frank stops by to give us a hand and a few laughs. Wray talks about an old student of his who built something rather remarkable and we say farewell to our friend Ed.
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Porsche 550 Dash Sculpting with a Mallet
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Porsche 550 Dash Sculpting with a Mallet
Back on the Porsche Dash! Wray keeps filling out the flexible shape pattern using the Metal Shaping Mallet and beater bag. He planishes it out using the English Wheel and then adds the details using a delrin hand tool. As you can see this is very time consuming which is why we need to go slow. One of Wray's many phrases is
"Hit, check, hit, check. and Not, Hit Hit Hit, check, oops"
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16
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1932 Studebaker Indy car racer replica
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1932 Studebaker Indy car racer replica
Gary Ash, from Massachusetts showed up at my shop with a dream about 4 years ago. He started taking coachbuilding/ metal shaping classes from me and at the class he worked on building his own 1932 Studebaker Indy car racer replica.
Previously, he had traveled to see several of the original six cars that were built, gathered folders and a laptop full of pictures and drawings. He had located a shop in Indiana that could make him a frame according to a drawing he had found in his searches. He had the correct style wire wheels, hubs, and knockoffs custom made in England. He had collected the correct Studebaker straight 8 engine, transmission, and rear end. All had to be rebuilt and modified.
After getting most of the chassis sorted out he came to my shop to learn how to make the aluminum body. I suggested that he make a wireform to get started and then take my class. At the class he got busy and also had some help from some of the other students.
Gary is now in the "I finished my project and I'm enjoying the hell out of it phase" Here are a few pictures of the build at my shop and his recent video of him taking his grandkids for a ride in his now registered Studebaker Indy racer. I'm sure his grandkids will get as much a thrill and inspiration from the ride in their grandfather's racer as Gary got from pursuing his dream to it's conclusion.
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Metal Shaping a Porsche 550 Dash (Part 3)
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Metal Shaping a Porsche 550 Dash (Part 3)
It's been a hot past few weeks but the heat wave has broke and we're back to filming! We still have the Porsche 550 dash and need to complete a copy of it before it leaves the shop. Since we shaped the other half of the Porsche dash, we are now working on the other side with the instrument panel.
We already made the Flexible shape pattern and gauges so we cut out a blank piece of sheet metal about an inch larger than the F.S.P. this ensure we have a little cheat room.
Wray start by hammering out the top of the instrument panel with a metal shaping mallet and beater bag. He smooths out the bumps with our big English Wheel and also use the small English Wheel for the valley. This video is just the gross development of the panel, once it fits the flexible shape pattern Wray will change the arrangement values and confirm it using the gauges. We hope you enjoy and thanks for all your support!
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