Technical Hammer form material.

I'm getting ready to make the rear windows for my coupe.
Usually I use mdf, but I want something a little more durable. Mdf is fine if you don't need to beat on it too much but these will need more than the mdf will take.
Mdf is easy to shape, cheap, and easy to get.

 

Cabinet makers multi layer plywood would probably hold up better, cost more though.

 

That dense plywood is called Baltic birch here.

Ive used eastern maple and if possible the end grain.

 

I have some furniture/cabinet grade plywood.
May give it a wack with the air hammer and see what happens.

 

laminate some Masonite?

 

You could mix up some fibergl*** resin, and cut it in half with acetone and coat your tooling. A couple thin coats would soak in and harden the plywood a bit. Might give it a little more life.

 

if you could get Delrin, i'll bet that would work. sorta like cutting board material

 

My local plastics supplier has a product called King Starboard.

Machines easily. You can use a wood router. Takes a decent beating.

 

I have some super fine cement that I was going to use to make a hammer form. I can't remember what it is called but can check tomorrow. My idea was to make the form hard and use s softer plastic/ rubber dead blow hammer to coerce the metal or to use the rivet gun / flow forming method.

 

I looked that up and watched the video, that looks like some really neat stuff!

 

We use starboard at work. It is tough and easy to machine. Doesn't sand worth a ****, get all fuzzy but a quick burn with a torch gets rid of the fuzz.

 

Could you please explain what your doing. I've never heard of hammer forming MDF,whats it used for ? Thanks

 

If you cruise thru my thread, around page 15 I made some hammer forms for the rear 1/4 windows. I need to make the rear windows now.
http://www.jalopyjournal.com/forum/threads/truck-into-a-coupe-my-next-pet-project.850807/

A hammer form is basically just as it sounds. A form made in the shape of the metal you want and the metal is beat into around, over, on the form. You can use a mallet, body hammer or air chisel type gun with different head.
MDF is medium density fiber board. It's sorta like solid cardboard.

 

I see , using it as a form or buck. Thanks

 

I used a old solid core door from a salvage place, 2" thick and cheap 20 bucks !

 

Here are a buddy of mine pics making a chopped back window opening for his "34 International pickup.

 

^^^nice^^^

 

Check a speciality supplier for rest room par***ions,they may have cut-offs or returned pieces.Hard plastic easy to shape,cut and router.

 

I used 2x6 fir to make my sub-rails, shaped easy and took a good beating making 16 gauge submit! I only need to make one and then did it all over again for other side. Looks like that's what this guy did. ( nicely too by the way! )

 

Vicky... When we were flying large control line model airplanes, I made a buck to hammer some metal over for cowlings. Standard indoor ply was soft, and only lasted thru 3 jobs... I made a new one, and bunched up an old nylon stocking, coating the wood surface generously with CyA (cyano acrylate glue, "Hot Stuff") and rubbing it in with the nylon. 2 applications made the ply hard as armor.
Easily cut and formed, then hardened after. It was 'the only answer'.
Try it on the ply you mentioned you have. (use the 'thin' CyA, and work it fast!)

 

Crazy glue?

 

Yeah, 'Crazy Glue'. 2 or more apps make wood real hard. Eclipses ******!

 

Lmao !!!

 

AK-DQ steel would help as well.

 

That's like hens teeth in these parts.
If you don't have anything to do and want some cheap entertainment
Call any steel supplier in the Ohio area and try asking for it. You'll be told it doesn't even exist.

 

I made this bezel for my rear window using a mdf hammer form and 20 gage steel. Held up fine. Bill

 

Really? I find that hard to believe!? Bummer.

 

Nice piece !

 

I can order it, 10 sheets at-a-time, and wait a week or two. Not sure what I'd do with 10 sheets.

 

I have two big blocks of douglas fir left over that I am saving to make hammer forms to shape some 3013 aluminum over, but douglas fir will probably be harder to find in Ohio than AK-DQ.