Hi, it's Ray from ProSaver Workshop in Pelham, Massachusetts
And to give you a little follow up on what we've been doing the last two classes with
Ed Scott. Ed is from the San Diego area and he spent all the time and designed this beautiful
like a 1950's Alfa Romeo proposal for a body design. It's his own design. And I've got
two other videos that we did on this showing some of the information about how he built
it and everything. But I just wanted to follow up on some of the issues that we had is creating
these little details around the grill, these little bead details. I'm going to show you
how we did that. And I also wanted to show the great work my students did. A lot of them
were first time English wheelers, first time shapers. And they've done some really good
work. We showed some of this before on the other video, but now we've added to it. And
we've got almost the whole rear fender now. This last class, Shane from New Hampshire
was able to knock out most of this rear fender. He had a little help from Esteban on this
fender on the back section. And then we welded it together. It's got a lot of the detail
in it that still needs to be tuned a little bit. We've got two door skins that were made
from Brian, I think from West Virginia. No, from Virginia. Part of the problem of building
this is you have to capture all this information. It's all about measurements. So there's quite
a bit of measuring that went on. A lot of the students learned the flexible shape pattern
system, which is my system. And a lot of people around the world are using it. And if you
try it, you're going to believe in it. It takes a little while to figure out how to
use it. If you come to my class, it's a lot easier to learn how to use it. We have a pile
two piles of benches of all the flexible shape patterns and the gauges that we need. And
most of this stuff is pretty on out. And it's just got to be dialed in so we can weld it
together. One more class and we're going to have like a half of a car. So we've captured
pretty much this whole side of the car minus the hood. We haven't done the hood yet. And
once we have all this information and get this all welded together, then we'll have
all the information for the other side and there will be other classes that do it. Or
Ed will bring this back to San Diego. He's got an enclosed trailer. Drive it across the
country and hopefully he'll learn enough skills so he can finish it at home. So it's coming
out really nice. The July class will be picking it up now. So I just wanted to show you this
little tool I made. Now a lot of people don't have a pole match. And a lot of times these
little accent beads, and Ed put a lot of them, and it's traditional on these Alphas too
around these drill openings and these little adjunct drill openings here, they would have
a little bead. So you could make a custom bead roller die or if you have a pole match
you can make little pole match dies. What I did was I purchased a whole bunch of this
Delrin. It's two inch by, let's see, might be one and three quarter by one off the measure
And I didn't know what I was going to use it for. But it turns out to be perfect to make
these little quick Delrin dies. So what I did was I took a little bit of clay. I've got a
lot of modeling clay. And took that modeling clay. This was the most defined bead that
he had right here. I thought I was going to be able to do these with a tipping wheel
I probably could, but it turned out it looked like it was a better deal to make this little
die set. So I went like that. And then you carefully pull it off and you'll get the exact
profile. And then I just drew that on a piece of paper the same size as that Delrin die
saw, Delrin stock. And then I cut the Delrin out with a bandsaw and then ground it a little
bit. So I've got a match pair of dies now to accommodate. This is 063 3003 aluminum
And you kind of kneel it right where the bead is. It'll make the drill a lot easier. And
these are locked in there, but they're a little floating. And instead of having a big, giant
pull match machine, which is expensive and a lot of people can't afford them and can't have
this, don't have the space for them. This is an old blacksmithing trick where you make this
nice little setup here. It's infinitely variable and you can do a lot with it. So I bent up
some aluminum here. This is 050. It's not a meal. And I'll put this in here right there
And that'll form that really nicely. So there's a little bead and it'll do a pretty nice result. Ed had started making this panel and
he was tipping this and I took what he had tipped and put it through that. And you have to
re-use the dies a little bit, but it'll make the turn. You got to mark off the edges of the die
So it will make that turn. And this panel here will be going right there and it gets welded to
this assembly here. That's part of the headlight flange and then the grill flange over here
It still needs to be tuned up a bunch and it'll be smoothed a little bit too. We can smooth it out
still. So that needs a little more attention. But I just thought that you'd like to see that
inexpensive solution to a common problem of making these little details. We still have the problem
here where these are tapered. So probably from here to here we might be able to use that tool
But then we've got to put this taper in and that tool won't do it. So we've got a few more problems
to solve as far as doing these little accent lines. On the rear fender, in the front fender it has a
nice little piece. We did that with the tipping wheel and you can also do it with an English wheel
where you put a real low frown or almost flat wheel on the bottom and then you just use that wheel as the
pull from and you pull down and you have a piece of tape watching the progress and you can put that nice
little piece in. We've got a piece on the trunk lid and on the hood too and those have got to be done
We'll probably do those with the tipping wheel. So I hope you enjoyed that and you can see what is
possible. A lot of people don't think they can do this but I prove over and over again that I can get students
with no experience whatsoever and with the right techniques and actually don't need a whole lot of tools
Just my shrinking facilitator, my gathering tool to allow the shrinking and the stretching and then an English
wheel and it can be one of my bigger English wheels or even a lot of students have been using my YouTube
English wheel. Okay so I hope you enjoyed that. It's Ray from Pro Shaper Workshop and please subscribe
comment and give us a like and hope to see you at a class soon. And remember, metal is clay