Shaping Aluminum Wheelpants DVD

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Shaping Aluminum Wheelpants: with 7 simple hand tools DVD

Color, 120 minutes.

Shaping Aluminum Wheel Pants

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TMV-0002-D $40.00

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TMV-0002-R $9.40

With seven simple hand tools (not including the torch, snips, mallet, stump, forming bag, slapper, dolly, and clamp), a set of wheel pants, a motorcycle tank, or some other closed hollow shape can be constructed. This tape introduces you to temper (hardness), thickness, and alloy (composition of the aluminum). You are shown how the metal behaves to certain working methods, such as stretching on the forming bag using a heavy metal shaping mallet, and shrinking using hand tools. When the metal is worked it "work hardens" and the strength increases - to a point. To avoid going beyond the point of workability and cracking or fracturing the metal, you are shown how to anneal the aluminum, using the Oxy-acetylene torch and a temperature indicator, in this case, soot and a Tempilstick (heat-level indicating crayon). You are shown how to take a 2 dimensional cocktail napkin sketch of a shape, and turn it into a 3 dimensional mockup, or EMT (engineering/manufacturing template) or station buck. We then divide the large complex shapes down into bite-sized pieces, using hand snips, paper patterns, and then making our blanks. Layout, cutting, deburring, and forming are shown in succession, with planishing to get the final fit as the last step. Finally you are shown the three standard metal shaping machines, the Air Power Hammer for rapid roughing of hollow compound shapes, the Pullmax machine, fitted with the TM Technologies thumbnail shrinking dies, and the English Wheel, for giving the precise shape and finish to a polished aircraft panel.
c 1995
2hours and 6 minutes
rated 4 stars (out of 4) by EAA
Used for years by the FAA to teach safety in the shop.
Rated by skinned Knuckles magazine as the best hand tool video available.
Images from this video are shown below
Patterns The student is taught how to make patterns, why they are used and the variations possible.
Mock Up By using the patterns we are then able to make a three dimensional representation of the part we wish to make. This is known as either a "mock-up" or a "buck".
Paper Patterns We now divide the part into bite sized pieces, using paper patterns for a variety of information.
Crowning Creating a crown or a swell by using a wood mallet and either a stump or a shot bag is a traditional process.
Smoothing Smoothing the roughed-in shape requires the use of the slapper and dolly . A quick clamping gizmo enables small panels to be worked with both hands.
Shrinking Shrinking by hand enables shapes to happen rapidly and limits the thinning of the sheet.
Checking Periodic checking on the buck keeps the panel headed in the right direction.
Panels The wheel pant is comprised of several panels, each made individually and then joined by gas welding . Here you see two such panels fit and then tack welded.
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