The first step was to make a paper pattern. The paper can actually tell you quite a bit about what has to be done to the panel to get the shape. Where the paper is folded, the sheet metal has to be shrunk and where the paper is tight, the sheet metal has to be stretched. The gold tape is just for some extra pizazz....
With the paper pattern fitting fairly decent, I outlined the edges of the hole with a crayon. I cut the pattern closer to the finished shape leaving about an 1/2" from the crayon line.
That was then transferred to a piece of 18ga and cut out using my $20 high quality Harbor Freight electric shears. Ironically, those shears have lasted years....I am truly impressed....
To start getting some shape in the flat panel, the center was stretched using a plastic mallet and a sand bag.....
....then the edges where shrunk on the Pullmax using thumbnail shrinking dies. At this point, the panel looks pretty bad. However, you can begin to see the edges curving upward.
After another round of stretching and shrinking the appropriate areas, the panel is starting to look like something usable. Even though its about the rough shape that we need, it too lumpy to do anything with. That's where the English Wheel comes in...
After a couple minutes with the smoothing action of the English Wheel, it's looking better...
With even more wheeling and the edges bent over, it's starting to fit nicely...
There still a bit more fitting and a little hammer and dolly work before it can be welded in, but it is getting close. More to come...
