The Cal-look Lounge

Here is a few step by step pictures On hammer forming and the man that taught me this process. Hammer forming is a way to make stamped looking parts at a very prototype process. But to start and I hope this doesnt bore you ! Back when I was finishing off my red notchback and getting started on my black ghia, About 1983-84. I wanted 4 wheel disk brakes . And I get wind of a old guy that was makeing disk brakes for linkpin kingpin spindles, Since the 70s ! And he ends up being one of the most talented men that I have ever met !!! So I get to dons house and he was in his little four car garage, And he was makeing splitwindow glove box doors by the way of hammerforming. So as we talk about brake stuff for a short period, I notice he was makeing something and had a few alum parts that looked stamped, setting on his work bench. So I asked him how they were made and he told me with these wooden blocks and hammered over the edge. So me being about 23-24 years old and thought I new everything, Told him that he was crazy and couldnt be done. So thats when he schooled me and when I started this almost 30 year metal working education. So back to makeing parts, First design and make pattern of part to be made. The transfer to form block material. Which could be alum or even sometype of hardwood. Softer material you can get away with hardwood, And for steel I usually use alum. And depends on how many parts your going to make ! So in the pictures the first pattern is used to tranfer onto material that parts are to be made from. and now we have a blank thats cut out and ground and filed, ready to be formed. As your hammering edge over, remember take your time and try not to hammer completely over in one hit !!!

Couple more shots of finishing off the part. If your patterns good, You shouldnt have any gaps in corners and welding will be effortless. For those that remember Gary topels red ghia and Joe hullets ghia and ted trubues yellow 68 bug from back in the day, Don oper did work on all those cars ! He also had a split with a porsche 5 speed and four wheel disk brakes built and never finished , in the late 60s or early 70s. He has since passed but not forgotten by the guys that knew him.

If anyone interested in a bracket , Let me know I am going to make a few.

Great post Danny! And thanks again to show a little bit of of the metal shapping art! (Don't you need  a student? I make the move to US  8) ;)l )

Do you think  it is possible to make stamps like yours with a vise, a ratchet socket and a piece of metal pipe? I have a set of sockets that looks to have a nice shape to do that.

Something that would be great to have some explanations, is hammering and dollying highs and lows spots. Especially high spots has I have a couple on the bay window bus I'm currently restoring. I have to use a torch, but I ended with some waves  :-\
It can be done with filler as I no more have high spots, but I know it could be better.

Thanks  ;)

Thanks J-F As far as stamps, are you talking about the hole flareing tools ? Yes you could probably use a socket or peice of tubeing and pull together in vise. As far as hammer and dollie work, There is alot to talk about! But one method is to push up on a low spot and lightly hit a high spot. Shrinking or friction dish helps sometimes with a high spot or just over worked areas bring them down. Most of all just practice and a little common since. The most important thing is getting all the length back into a panel from what caused the damage, Think of it like a folded peice of paper, grab each side and pull. The more you pull the less wrinkles you have ! There is a good metal working forum called metal meet.com   you will like! Well I hope that helped in some way!

Thanks for the link Danny. I'm going to check it out  ;)

Danny, I think there might be some interest in a similar bracket for the Holley pump...