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THE BORZOI - PANEL FORMING
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A good way to learn how to form metal, is to build a car from scratch. Be prepared to get dirty and to make a few mistakes. Ally sheeting is expensive, so also be prepared to get in trouble with the girlfriend. Ally is softer than steel and easier to form, but is much harder to weld, and you are likely to need specialist welding equipment.
Nelson Kruschandl making the Borzoi's alloy bodywork
I was a jeweler for a time, hence used to small tolerances, and used to forming metal into shapes. You may want to try bending wire into accurate shapes before trying to shape panels on sheet metal. If you cannot weld, use pop rivets. Some of the panels in the body above were formed over my knee. For tight radius bends, use a vice and angle iron to fold the metal.
With practice and precise marking using fine tipped felt markers (Projector) you can make surprisingly nice parts. Remember which side of the line you are bending from - now worries. I used tin snips and an electric jigsaw to cut the sheets. When cutting frequently blow the filings away to stop surface marking.
See the Car development build stages and features below:
Borzoi Chassis | Borzoi Bodywork | Borzoi Joystick | Borzoi Styling
CHASSIS | LOADING-SERVO | CARTRIDGE | MOTORS | INSTRUMENTS | WIND-TUNNEL
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