I'm a novice sheet metal guy, I have the most rudimentary tools, crappy bead roller, some body hammers/dollys, shrinker/stretcher, bench top english wheel, mig welder, etc. I'm installing new rear wheel tubs in my 55 and the transition from the inner quarter to the wheel well is rusty. What would be the easiest way to make these pieces for both sides? I think the lower part will be the hardest, but I'm more concerned about just making the curve all throughout the length of the tub right now, and figure that part out later. I don't mind buying one or two tools but I don't have a whole lot of room to keep big tools in my two car garage. What would be the easiest way to approach this? Better bead roller with tipping dies? Or maybe get a heavier, better english wheel and use it with the shrinker stretcher to for the curves? Is there an easier or better way that someone could elaborate? Or a way I can make it with what I have? I also don't really have anyone local that I know of that could assist me in making these. Any help would be appreciated. Thanks.
Take a piece of steel 2-3" wide, (or wider if needed) bend a 90 along it's length then use a stretcher along the top edge to get the curve you need.
Thought about that, wonder if the radius will be too tight, it would work, but it’s such a soft transition between the two. Not that I need it to look super factory, but would be nice if you couldn’t tell it was patched.
If I was to brake it over a piece of tubing to get the same inner radius, could I still do the same thing? Just stretch the top?
Hammer and shot bag on your sheet metal, check fit 5 million times, then smooth out your hammer marks with your English wheel, test fit 2 million more times Then maybe it'll fit.
You don't necessarily have to make it all in one piece. If you can't get enough arc shrunk/stretched into it with a gentle curve, just make several pieces. Maybe a 5" wide strip with the arc, then another below and another below until you've formed the top to bottom section. You'll have extra seams to weld, but it would work without needing any overly fancy tools. That whole section of trunk is reproduced as well, although I'm sure you're trying to avoid buying a new panel vs. just making something yourself, which I totally understand and would do likewise.
Make a pattern. The poster board will show you what to do. Bending is easy after that. buying tools is up to you. I have built tubs by tuck shrinking and hand planishing. the ability to shrink and stretch with a tool is limited by the tools depth. For lips or bends that are not straight I will make a pattern, lay out the bend and use pliers or a hammer and dolly to make the bend. This eliminates the need to stretch it shrink to make the entire shape. sounds like you have everything you need. for deep curves, make the part in 2 pieces. Weld in the center of the radius.