Metal working in the rain
Getting started converting cardboard templates to metal parts. Here's the tool of choice: $40 electric shear from Harbor Freight. Forget the air nibblers. They are useless without a very serious air tank.
![](http://i772.photobucket.com/albums/yy1/DarrinVallis/DasBeast/20161105_102153%20576x1024_zpsayg4w5cm.jpg)
Here's the back deck taking shape. It conveniently started pouring rain.
![](http://i772.photobucket.com/albums/yy1/DarrinVallis/DasBeast/20161105_105522%201024x576_zps5rdufm4c.jpg)
Impressive results so far.
![](http://i772.photobucket.com/albums/yy1/DarrinVallis/DasBeast/20161105_103743%20576x1024_zps16zglnn6.jpg)
Forming the upper inside piece
![](http://i772.photobucket.com/albums/yy1/DarrinVallis/DasBeast/20161105_111424%20576x1024_zpsr5zc9znm.jpg)
Fits nicely
![](http://i772.photobucket.com/albums/yy1/DarrinVallis/DasBeast/20161105_114437%201024x576_zpshhsk0erf.jpg)
Forming the lower piece
![](http://i772.photobucket.com/albums/yy1/DarrinVallis/DasBeast/20161105_123931%201024x576_zpsrrc48vq9.jpg)
Our ghetto metal break using 2x4s and clamps
![](http://i772.photobucket.com/albums/yy1/DarrinVallis/DasBeast/20161105_124120%201024x576_zpsw7xrasr7.jpg)
Excellent results given the available tools. Needs a bit of trimming.
![](http://i772.photobucket.com/albums/yy1/DarrinVallis/DasBeast/20161105_125414%201024x576_zpsruscoip9.jpg)
Final product looks great.
![](http://i772.photobucket.com/albums/yy1/DarrinVallis/DasBeast/20161105_125437%201024x576_zpsbjzjy3rk.jpg)
Cutting out the roof patch.
![](http://i772.photobucket.com/albums/yy1/DarrinVallis/DasBeast/20161105_130036%201024x576_zpsz8hdixly.jpg)
Practicing hammer shaping metal so it conforms to the roof
![](http://i772.photobucket.com/albums/yy1/DarrinVallis/DasBeast/20161105_133507%20576x1024_zpse4vh0mtc.jpg)
![](http://i772.photobucket.com/albums/yy1/DarrinVallis/DasBeast/20161105_133532%20576x1024_zpsebhvtbp0.jpg)
We used the compressor tank as a large radius bend press.
![](http://i772.photobucket.com/albums/yy1/DarrinVallis/DasBeast/20161105_141357%20576x1024_zpsk0r2g1dk.jpg)
Here it is in place. Not bad quality. Definitely good enough for a race car.
![](http://i772.photobucket.com/albums/yy1/DarrinVallis/DasBeast/20161105_142345%201024x576_zpsh3ldznol.jpg)
Metal prep, clamping, bonding and sheet metal screws next.
Getting started converting cardboard templates to metal parts. Here's the tool of choice: $40 electric shear from Harbor Freight. Forget the air nibblers. They are useless without a very serious air tank.
![](http://i772.photobucket.com/albums/yy1/DarrinVallis/DasBeast/20161105_102153%20576x1024_zpsayg4w5cm.jpg)
Here's the back deck taking shape. It conveniently started pouring rain.
![](http://i772.photobucket.com/albums/yy1/DarrinVallis/DasBeast/20161105_105522%201024x576_zps5rdufm4c.jpg)
Impressive results so far.
![](http://i772.photobucket.com/albums/yy1/DarrinVallis/DasBeast/20161105_103743%20576x1024_zps16zglnn6.jpg)
Forming the upper inside piece
![](http://i772.photobucket.com/albums/yy1/DarrinVallis/DasBeast/20161105_111424%20576x1024_zpsr5zc9znm.jpg)
Fits nicely
![](http://i772.photobucket.com/albums/yy1/DarrinVallis/DasBeast/20161105_114437%201024x576_zpshhsk0erf.jpg)
Forming the lower piece
![](http://i772.photobucket.com/albums/yy1/DarrinVallis/DasBeast/20161105_123931%201024x576_zpsrrc48vq9.jpg)
Our ghetto metal break using 2x4s and clamps
![](http://i772.photobucket.com/albums/yy1/DarrinVallis/DasBeast/20161105_124120%201024x576_zpsw7xrasr7.jpg)
Excellent results given the available tools. Needs a bit of trimming.
![](http://i772.photobucket.com/albums/yy1/DarrinVallis/DasBeast/20161105_125414%201024x576_zpsruscoip9.jpg)
Final product looks great.
![](http://i772.photobucket.com/albums/yy1/DarrinVallis/DasBeast/20161105_125437%201024x576_zpsbjzjy3rk.jpg)
Cutting out the roof patch.
![](http://i772.photobucket.com/albums/yy1/DarrinVallis/DasBeast/20161105_130036%201024x576_zpsz8hdixly.jpg)
Practicing hammer shaping metal so it conforms to the roof
![](http://i772.photobucket.com/albums/yy1/DarrinVallis/DasBeast/20161105_133507%20576x1024_zpse4vh0mtc.jpg)
![](http://i772.photobucket.com/albums/yy1/DarrinVallis/DasBeast/20161105_133532%20576x1024_zpsebhvtbp0.jpg)
We used the compressor tank as a large radius bend press.
![](http://i772.photobucket.com/albums/yy1/DarrinVallis/DasBeast/20161105_141357%20576x1024_zpsk0r2g1dk.jpg)
Here it is in place. Not bad quality. Definitely good enough for a race car.
![](http://i772.photobucket.com/albums/yy1/DarrinVallis/DasBeast/20161105_142345%201024x576_zpsh3ldznol.jpg)
Metal prep, clamping, bonding and sheet metal screws next.
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