Using a hydraulic press and lasercut jigs to make basic car panels, Mk1 Ford Capri
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- Опубліковано 6 жов 2024
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I’m really glad you got round to making these videos. They’re a great reference for a potential panel purchasing customer to see how much work goes into making them. Brilliant 🤩
Cheers Trevor, im strangely almost enjoying making the videos so far.
Fantastic work! It gives me an appreciation for how expensive it is to tool up a production run.
Nothing is cheap these days especially the price of steel.
Just came across your channel and subscribed. Very satisfying watching the panel take shape. Awesome job sir!
Thankyou.
This is amazing and who are you kidding this isnt basic, very good work.
Thankyou
Holy smokes, that's incredible!
Appreciated, thankyou.
At only a minute and half into the video I can see this is a brilliant method. I don't have a cnc laser table, but I do have a cnc plasma table. I have thought of things like this and you're showing us the practical side of how to make it happen. Crazy ideas are one thing, but making it happen is entirely another level of thought and action. Well done! EDIT: I've watched all the way to the end now and it's absolutely genius! I can picture your method being extended to making the reliefs on hoods and doors, with the press lines left in, almost like an elevation map. A whole new family of lined designs. Very cool and inspiring!
Thankyou for the kind comments. Id be interested to see how you could go with a plasma. My initial thoughts would be that it would be harder to achieve accurate clearances between the jig parts. I guess if its your own machine then it wouldnt cost you anything to have a go. Im going to do a similar video on a battery tray that i make in a similar way but its another step up again with sections that are drawn up maybe an inch or so, its pretty impressive how close to or better than factory the results can be.
That was a real pleasure to watch and makes me wish I’d taken the time and effort to pick up a practical skill like this. Also really good how you talk through all the little details you need to consider when producing a part like this.
Thanks for the feedback. Its hard to talk while actually making a part. Hopefully i can improve the filmography
This is amazing! Excellent craftsmanship, very informative.
Thankyou.
I am genuinely in awe of what you can do. Such talent and in a down to earth, humble fashion. Hugely impressive
Thankyou.
Good stuff, well thought out and neat..from a crusty old tool/panel maker in the uk
Thanks for watching!
Amazing metal work skills from another Aussie, great work on the die making, well done mate.
Theres still a few good ozzies around.
Very nice job. Just found your channel. Very impressed.
Awesome, thank you!
Wonderful work and amazing skill. Thoroughly enjoyed that, subscribed 😉👍
Awesome, thankyou.
Great work and detail presentation! Wish you success!!
Thank you very much!
Nice looking panel!
Thankyou
Excellent work. Nice walkthrough of how to dial in pressed sheet metal parts.
Thanks for the feedback. I have a more complex part to film in the coming weeks.
Nice work Elliott, you're a humble man. Keep the great videos coming 👍
Thanks, will do!
Brilliant! Loved the clever and simple breakdown on the different tools and press stages
Thankyou.
Excellent work and craftsmanship there. A pleasure to watch.
Thank you very much!
Very nice process. I make a lot of similar parts for a different make of car. I have had some luck using rubber and polyethylene male "punches" Both for forming and for touch up like on the little wedge shaped cut out. It's kind of like hydro forming and saves the effort involved in making so many metal press parts. Works well for making raised stiffening ribs on flat panels.
I think that I saw a video of someone using that process to make sheetmetal parts. I think that it was a guy making home made aircraft parts. Naturally it is very important to make such parts smoothly and cleanly to avoid tears or stress points in that sort of application.
Mark from Melbourne Australia
@@markfryer9880 Yup, I use a process that's a bit more "open" than the airplane guys seem to use, but the results are similar. I generally use synthetic "stone" counter top material (corian) for one half of the tool and rubber for the other half. I also have one die made from special filled epoxy made for the purpose of low volume press tooling Most of the parts I make are in quantities that are small enough that full-on tooling is not economical and neither is one at a time. There are very few parts that I have made more than 100 of and many that I have made tens of. So, kinda caught in the middle volume-wise.
@@edwardtaylor4785 How do you shape the Corian?
@@piersvellacott5710 Corian, and other similar products, can be worked with ordinary carbide wood working tools. If required, it can also be heated and bent if the shape requires it. I use the resulting form in two basic ways. When possible, I do as much of the forming as possible with a rubber "male" punch in a hydraulic press because it is fast and produces a nice smooth part. I have the luxury of a 37 ton platen press, but an ordinary H-frame press will work too. Corian is brittle and the form must be very well supported or it will crack. For fine details, rolled edges and such, I use an air powered rivet gun with a variety of HDPE tips attached to it. I don't use tools that are harder that the material being formed to avoid marring the part or getting unwanted "smiles" that have to be fettled later. Just trying to form it, not damage it. Google "flow forming" and you will probably find some additional information on the topic. BTW, for a "one off", I have seen some folks use MDF for the form, but the Corian type material is more durable if you're doing multiples.
Ive seen a few guys use the rubbe die technique, not tried it myself, i dont have a 3d printer but i think that in combination would be usefull in intricate parts
This work is quite impressive , and it shows how much time it takes to do this, appreciate the video mate thank you
Glad you enjoyed it
Impressive! Congrats!
Thanks!
Hiya Elliott have just found your channel amazing work well done it shows how much goes into making panels that the Jo bloggs don't see Inc myself I'm now a subscriber too ♥️👍
Awesome, thank you!
Beautiful demonstration, keep up the good work.
Thank you! Will do!
Well I’m very bloody impressed, and subscribed! 👍
Thankyou
Nice job mate 👍
Thanks 👍
Excellent work my friend. Very inspiring and great to see it doesn’t need a super heavy press.
Subscribed!✊
Awesome thankyou. I sometimes crank the press down harder but rarely need the full 10 tonnes of this little press.
Great job and details!
Thanks!
Excellent video, well done. All you need now is a cnc plasma cutter and you can make your own dies. The crossfire CNC plasma cutter is an affordable machine from Langmuir Systems in the US and ships down under. I cut 17mm mild steel with no issues with a unimig razor cut 45.
Id love one, just not top of my list at the moment. Im chasing a descent lathe when finances allow. I have a good relationship with the lasercutting company that I use and the turnaround time is short.
@@elliotaw it’s interesting that the laser cuts are not straight when cutting thick metal, I assumed they would be perfect. The plasma cutter also shares the same issue.
@@digitalbase9396 in thin plate upto around 5 or 6mm thick it is not measurable but the thicker you go after that can make a big difference especially if making parts with tight clearances.
Brilliant work and very informative video. Thanks 👍👍
Nice work.
I have been using this technique on some of the stuff that I’m working on. I have plans to do small runs of the panels for the FIAT Dino and laser cut tooling is exactly what I need so to see how well your tooling works is really useful.
I look forward to seeing more of your work.
Ive found if you get the clearances right between the press jig parts you can get a good run out of them. Some of my jigs have produced over 200 parts with little to no wear on the jig edges at all.
@@elliotaw it’s the accuracy and it’s repetition with your alignment jig that I am really impressed with. The Maserati stuff that I work on is mostly hand formed and I do make formers for some jobs.
But the FIAT stuff is machine stamped much like the FORD and this is where I plan to emulate your production method .
As you mentioned it’s keeping the part aligned and centred can be difficult.
Understanding how the metal will stretch and pull moving and changing the position or size of the holes.
The Maserati air vents video on my channel might interest you as I use a similar technique.
A lot of the job is knowing how to make the tooling to make the part and that’s what I think is really impressive to see in your work and your video.
Making accurate well fitting panels is what I’m going for. The biggest issue is finding enough information as reference to reproduce what is required for the restoration of the FIAT Dino in the first place. If it’s not rotted out then it’s been replaced with something that is completely wrong.
@@marksitaliangarage I just watched your Maserati vent video, ive also subscribed to your channel. I have a close friend here in Melbourne who will love the cars you are working on, he is pro English people and Italian cars so he'll be watching all of your youtube channel for sure. It's interesting how much of a deep draw you can achieve with the press method without bruising or tearing the metal. I have a jig setup for some battery trays that I make and that has some deep profiles and is way more detailed than the headlight panels that I filmed the other day. Was interested to see how you went with the rubber die method, ive not tried it myself but have seen the shermans making use of that technique with good results. I'm guessing you'd almost have to add 10% or something to the male die dimensions to get the draw lengths right ?
@@elliotaw i used aluminium for that one I think it would not be very successful with steel unless it was under 0.8 mm .
I think it would work well for brass and copper for trim pieces that sort of thing.
I made a trim piece for the handbrake surround on a Dino Spyder In aluminium with this technique it worked well and the customer was very happy with it. The best thing is that you don’t need to worry about alignment as you are only using a male die.
Excellent work mate. Link shared in the Uk so hope it gets you a few more sales. Keep up the great work. Cheers Glenn
Thanks Glenn.
Brilliant! You make a very fine part.
Thanks.
That is a very impressive video Elliot. You make it look very easy, which I am sure it is not. I will do some research into laser cutting near me. Thanks for taking so much trouble.
On my UA-cam channel I tend toward repairing mechanical things but I quite fancy your system using my hydraulic shop press for some parts for a Porsche 914 I am working on.
If in the search box on UA-cam you type in my name "Tony Hillyard" you can have a tour. Thanks again for a superb video.
Plenty of laser cutters around. Id contact a few if possible as their prices and cut quality can differ somewhat. Will check your channel out, cheers.
Very well done, thanks for sharing. Subscribed!
Thankyou.
Cool always wondered about doing this type of work
Cheers
Glad to help
I've been using exactly the same techniques plus some others to make some Porsche panels. I totally agree about developing the tooling and the blank being iterative. Patience is required, but the results can be very good. The tooling can get almost unmanagably heavy for bigger panels. I'm going to make a frame to extend the bed on my press so I can press locally at one end of a long panel without having to support the weight of the other end of the tool myself.
I hear you. The biggest panel ive made using this technique was probably twice the size of this one and as you say it gets heavy loading it all in and out of the press.
@@elliotaw That's probably about the time that you need an engine crane or an overhead gantry crane and possibly a bigger workshop!
Always need a bigger workshop.. thats just a man rule !
Very ingenious!
Thankyou.
Very nice. I have used panel forming to do floor pans and have thought about using a press, unfortunately I don't have one that would be large enough to fit the forms. Something to think about.
Even a half floor would be problematic without a sizeable press. Id imagine a quarter section could be done. Into bead roller or pullmax territory to do a full floor.
Well done, man!
Thanks
Amazing work. Would it not be easier on the square holes do only to small alignment holes until after its stretched and then broach the rectangles to exact size after that? Would allow more metal to draw from when stretching that final dimpled shape.
I think if you wanted them holes to be 0.0001 tolerance then doing them afterwards would be a better way to go but I think they only take a plastic clip so plus or minus 0.1mm shouldnt cause an issue.
Very impressed with that! Well done. That must have cost you a serious amount in time and labour, to get those jigs produced, then the time it takes for the pressing processes. Then you hand finish them! I hope you get suitable remuneration for just one of those. In the UK I'd expect to pay a minimum of £65 each plus the dreaded VAT here in Britain( + 20% of price to the bloody government! )
Nothing is cheap these days. I have set my price to roughly match my competitors. A lot of people will shop with budget over quality unfortunately. If I do a big day on them it makes it financially worth while in the end when they are all sold.
20% VAT Ouch! Makes our 10% GST look reasonable in comparison.
brilliant mate
Cheers
Quality!
Good luck with your channel brother
Fingers crossed and thankyou.
Great stuff Elliot
What sort of money did you invest in the nests and press plugs.
Laser cutting the parts and steel cost.?
I suppose you used the centre cut out of the perimeter frames to form the centre plug just filed/ ground a bit more clearance to allow for the sheet metal.
18 gage or 19 gage??
I have seen a few guys doe the same metal basic forms and use an air chisel with a head with a hammer or a rounded chisel shaft to hammer form over the nest particularly low number or one off parts.
I dont use the scrap centre slugs for the jigs as the laser cut width doesnt match the steel thickness. I use 19 gauge ca3. Cant remember the cost of the lasercutting to be fair, it was a while ago i had them made, id be guessing around 6 or 700 bucks au.
That is wonderful, although the setup jig is a lot of work and lot of materials. If you dab a slight film of tallow, engine oil or grease on the panel where the pressure areas are, then your pressings will not tend to stick and come out smoothly.
I usually use a light oil on everything. i didnt on this occasion while filming because i didnt want to have to keep handling my camera with oily hands.
@@elliotaw Quite understandable in the circumstances.
Amazing.
Thanks!
Phenomenal!!!!!!
I learned a lot thanks
Glad it was helpful!
One more subscritor. Excellent!
Thankyou
Very neat work.
The hydraulic press shaft doesn't appear to be quite vertical. I guess it is usually not a problem but could get worse??
How do you sell the parts you si cleverly make?.
Spain
Might just be the camera angle. The cylinder is definately vertical. Though i leave the mounting bolts loose so it can slide from left to right along the frame easily.
Not in for cars, But I like to work with metals😛But what really caught my intrest in your vid, is that pedal for your hydraulic press. Have you made it yourself? Just pushed the sub button mate😉
Its an air powered hydraulic pump. Its supposed to be on the floor and foot operated but i find more control using it on the bench with my hand. Theyre freely available, you can get one made of chinesium for a hundred bucks or so or a high end one for a grand or thereabouts. My one is middle of the road pricewise. A well worth upgrade for any hand pump operated press.
@@elliotaw Thank you very much Elliot🙂 Btw really good vid n work, keep em coming mate🍻
😎🤙
nice panels but like you said, you need to be making a load at a time to justify the amount of work in the tooling. i thought you could have threaded the holes for the lugs to make the dimples and simply wound the bolt in maybe?
Yes that would work quite well i reckon. good thinking.
@@elliotaw yep, more than one way of skinning a cat. i think we're all guilty of being blinkered from time to time. in my job which has been fitting kitchens and bathrooms etc, for too many years, i often see some other fitters that are pretty rubbish, but then i spot something they have done, and thought, that's a good idea, even though a lot of there work is pants. just goes to show you, we can learn something every day.
👍👍😎👍👍
I hate you! 😆 Nevermind, I go tried again...
Err.. thanks.. i think....lol
Use a flat to distribute the press pressure instead of round bar and lift your press surface up to the top hole.
Have you tried using lubricant the surface being pressed?
Nice work though.
Well done.👍
I do normally lubricate everything. Just decided not to for filming purposes. Would work better to spread the load, i have a few press dies from closed down engineering shops but they get heavy and unweildly to handle.