Sheet Metal ShapingOn Episode 6 of the "Sheet Metal Shaping Podcast" we have California legend Ron Covell of Covell Creative Metalworking
In the episode, we cover everything from early beginnings of metal shaping, to shaping techniques, to the modern era of Youtube operations.
We also discuss:
- Ron's extensive history in sheet metal shaping - Being a business person vs a trades person - Aluminum vs Steel - Teaching the skills of shaping metal, 648 workshops + 8 counties outside of USA - Writing for hotrod magazines over past 35 years - Making a bomber seat - Making bucks, napkin sketches, and patterning tips - interpreting photographs to recreate components - mirroring components from the left side, to the right - Sensitivity to shape and the importance of good design - Going to art school and transferable skills - What students struggle with the most - Freedom of choice in the retirement years - Being friends with Lazze metalshaping
Ep 06 Bomber Seats and Buck Building w/ Ron Covell of Covell Creative MetalworkingSheet Metal Shaping2023-08-24 | On Episode 6 of the "Sheet Metal Shaping Podcast" we have California legend Ron Covell of Covell Creative Metalworking
In the episode, we cover everything from early beginnings of metal shaping, to shaping techniques, to the modern era of Youtube operations.
We also discuss:
- Ron's extensive history in sheet metal shaping - Being a business person vs a trades person - Aluminum vs Steel - Teaching the skills of shaping metal, 648 workshops + 8 counties outside of USA - Writing for hotrod magazines over past 35 years - Making a bomber seat - Making bucks, napkin sketches, and patterning tips - interpreting photographs to recreate components - mirroring components from the left side, to the right - Sensitivity to shape and the importance of good design - Going to art school and transferable skills - What students struggle with the most - Freedom of choice in the retirement years - Being friends with Lazze metalshaping
Follow us @sheetmetalshaping on instagram and Like/ Follow/ Share/ Subscribe to our channel for more great guests.
#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #roncovell #dragster #hotrodEp 33 | No Stunt Wrenches I Behind The Scenes and Current Projects w/ Stacey DavidSheet Metal Shaping2024-09-26 | On Episode 33 of the "Sheet Metal Shaping Podcast" we have TV personality and true gear head, Stacey David from Nashville, Tennessee.
In this episode we chat about what goes on behind the scenes when the cameras aren't rolling, what projects he's working on, and why he's passionate about metal work
We also discuss:
- How the TV shows got started - “What are you working on?” - 10-15 projects on the go - Writing books, and the levels of restoration - 80% of people never finish their project
- “People will not pay for your labour” in certain restorations - People go back to what they remember having fun with (sentiment sells) - Getting started in TV and being a professional musician - Working with major tv networks vs social media generation - Nothing lasts forever in any industry
- Making a switch from employed to self employed - Couldn’t make money on a straight up metal show, theres no product to sell - Getting a big block Chev 572 months before Jay Leno - Being an advocate for skilled trades like @ Mike Rowe - Becoming a competitor to your previous employer
- Giving credit to those who help along the way - TV shows used to be the big money maker, now social media has taken over - Replica and kit cars taken off in the industry - Working on the Swamp Sprite + fabrication style - The “Hot Rod” English wheel
- 2 types of content: Start to finish story per episode vs “how to” - Proper shop organization for efficiency - Honest review of Dake Power Hammers
Shout outs: Ron covell @RonCovell Mike rowe @therealmikerowe Eastwood @eastwoodco Dake Tools
Follow Stacey on Youtube @OfficialStaceyDavid and on Instagram @officialstaceydavid, and www.staceydavid.com
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #hotrod #powerhammer #baileigh #baileigharmy #baileigh_industrial #yoder #metalshaping #pettingell #welding #staceydavid #gearztv #trucks!Ep 32 | Don’t Give Up Your Values I Secret Projects and Security Detail w/ Matt SalamancaSheet Metal Shaping2024-08-12 | On Episode 32 of the "Sheet Metal Shaping Podcast" we have Matt Salamanca from Santa Ana, California, USA
In this episode we chat about what's rolling around in Matt's shop these days, how he started his business from ground-zero and how honesty is the best policy.
We also discuss:
- Musician to metal shaping - Utilizing the online forums for learning in the early years - Importance of his Mom in his life - Taking classes from other industry pro’s - Harbor Freight English Wheel is the gateway tool to the craft - Music helped shape the way he thinks - Dunning krugar effect, thinking you know and you don’t
- Starting a business and learning the craft, Thousands of hours - Taping a dolly to his knee, 1 arm bandit - Internal pursuit of perfection - Defining the business, starting with a roof chop - Thinking of metal shaping like a sport, always practicing - The best, defined as time, speed, quality
- This business is hourly, getting comfortable with the anxiety that can persist - Thinking steps ahead on a project - Turning off of social media - Investing in his skills + reputation, off the clock - Working on the Jag with Foose Design
- Learning to teach others is a skill builder - Trying different power hammers, borrowing tools from a friend - Even if you don’t have talent, Just don’t quit - Averaging 7 days per week for 10 years - Working on a 550 porsche custom, long term project - Where’s the industry headed? - Being cautious with customers on how deep to get with certain projects - Does it need to be perfect? Or need to be done?
Mentions: Mark Scranton The hamb Ron covell @RonCovell Hollywood hotrods @HollywoodHotRods Ken sakamoto Wray Schelin @proshaper Steve Sheppard Rod emery @rodemory Ed scutchfield Mike kleeves Red tweit Scott knight Chip foose @FooseDesignInc Geoff moss Sollis metal shaping Bobby walden @waldenspeed
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #hotrod #powerhammer #baileigh #baileigharmy #baileigh_industrial #yoder #metalshaping #pettingell #welding #salamancametalcraft #mattsalamanca #salamancaEp 31 | 40 Designs Per Day I Prestigious Cars, Economics, and AI Strategy w/ Wray SchelinSheet Metal Shaping2024-08-06 | On Episode 31 of the "Sheet Metal Shaping Podcast" we have Wray Schelin from Pro Shaper Workshop in Charlton, MA
In this episode we chat all about prestigious cars of the past, economics of how those cars are valued/ why that's important, and what he's doing with AI to create beautiful cars of the future.
We also discuss: - History of how he got started + grandfathers influence - Identifying opportunity/ Progressing from boat to car restoration - Auburns, Dusenbergs, and many other prestigious restorations - Economics of car restoration - Working in 2 car garage for many years
- Moving the “maglio” hammer into his basement for noise control - Making Jaguar parts sold via mail order - Moving to a 3000sf mid size shop in Connecticut - Upgrading to 20,000sf shop in Charlton, MA - Hiring and firing employees in his business
- Being a shop manager vs being a business owner - English, Italinas, French, Americans metal shaping styles - Wide upper wheel / pattern wheeling - Flexible shape patterns - Preference of English wheel vs reciprocating. Hammering machines
- The beauty in Italian design - Wood station buck vs wire form, preference - Using .080 vs. other thickness material for coach building - Ai design – creativity and productivity tool - “You don’t want a (mechanical) vintage experience” driving an old car
- Ai design cars, are they worth anything? - Making 40 designs every day - Working 9am – 11pm every single day
Mentions: Matt Salamanca John Glover Chris Runge Ken sakamoto Tom lipton Ox tools Metalmeet @metalmeet
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #hotrod #powerhammer #baileigh #baileigharmy #baileigh_industrial #yoder #metalshaping #pettingell #welding #wrayschelin #proshaperEp 30 | All About Metal Shaping Bucks | Real World Examples w/ Kerry PinkertonSheet Metal Shaping2024-07-23 | On Episode 30 of the "Sheet Metal Shaping Podcast" we have Kerry Pinkerton from Alabama, USA
In this episode we chat all about metal shaping bucks, pros and cons of each, what do they cost, how to build it
We also discuss: - Started imperial wheeling machines, sold to pat brubaker - Designing his own art deco coupe, several times over - Welding 2 reverse curves together becomes challenging to arrange
- Egg crate (plywood) bucks, pros and cons - Solid bucks used like hammer forms - Lofting w alum welding rod/ strips - Contour Gauges, pros and cons
- Shape vs Form - Touching on allmetalshaping.com and metalmeet forums - “Burt Buck” How to’s - Wray Schelin’s @proshaper “Flexble Shape Pattern” (flexible/ reversible buck) - Metal flows in the path of least resistance
- Bondo Bucks w/ short strand filler - Symetry, fenders being 1.5” different side to side - Butcher paper/ cardboard patterns – speed vs accuracy - Foam bucks surfaced with body filler
Mentions: Luc de ley @marcelscustommetal Wray schelin @proshaper @proshaper Metalmeet @metalmeet Allmetalshaping.com Pat Brubaker @imperial_wheeling_machines
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #hotrod #powerhammer #baileigh #baileigharmy #baileigh_industrial #yoder #metalshaping #pettingell #welding #kerrypinkerton @allmetalshaping.comEp 29 | Kennedy Coachworks | Alfa Romeo TZ2 Inspired Tribute w/ Craig KennedySheet Metal Shaping2024-07-09 | On Episode 29 of the "Sheet Metal Shaping Podcast" we have Craig Kennedy from Kennedy Coachworks in Colorado
In this episode we chat origins of Kennedy Coachworks, and his Alfa Romeo TZ2 inspired tribute car.
We also discuss: - Starting at a restoration shop - Mentors getting started in the coach building trade - Starting Kennedy Coachworks in 2018 - Employed vs Self Employed Comparison - Being self employed/ working back - In the shop: Jaguar XK120, Pantera, 1965 Impala, Maserati Ghibli SS Spider
- Scratch building a classic body, Alfa Romeo TZ2 Inspired, Miata Platform - Adjusting body profiles to suit his taste - Getting started with the body design, scale, proportion from a model - Designing the buck in CAD + Building a CNC router - Wood buck preferred for rigidity
- Working with wood bucks - @howisthatstreetlegal foam bucks - Working with aluminum, why 3003 vs other alloys - Making his own tooling for headlight buckets - The importance of learning hand tool basics first, before power tools
Show Mentions + Shoutouts: @howisthatstreetlegal Fay Butler Renato Moskovich Terry Steagall
Follow Craig @craig_the_welder on IG
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #hotrod #powerhammer #baileigh #baileigharmy #baileigh_industrial #yoder #metalshaping #pettingell #welding #colorado #kennedycoachworks #craigKennedyEp 28 | Walden Speed Shop | Early Origins of Hot Rods + Shaping Metal w/ Bobby WaldenSheet Metal Shaping2024-06-26 | On Episode 28 of the "Sheet Metal Shaping Podcast" we have Bobby Walden from Walden Speed Shop in Pomona, California
In this episode we chat origins of Walden speed shop, California Metal Shaping, and Bobby's 1963 Yoder
We also discuss: - Street rodder magazine changd his life, Oct 1984 - Scott Knight in street rodder magazine+ Seminars - Scouring the USA for sheet metal equipment 1980’s/ 1990’s pre-Internet era - Getting a co-signer to buy his first power hammer - Meeting Fay Butler, Ron Covell, at Scott Knight’s seminars
- Economics of metal shaping - Listen to your customer - Social media truths and otherwise - Operating a shop like Troy Trepanier and Jack/ Judy Trepanier
- Making 500 Cars like Roy Brizio - Giving credit to others with talent who contribute - Buying Yoder inventory from Clay Cook - Setting up a power hammer properly - Opinions on “stealing other’s ideas”
Show Mentions + Shoutouts: Wesley Kent @wwkentdesign Matt Bryant of haze city fabrication @hazecity36 Roy Brizio @roybriziostreetrods Troy Trepanier @rad_rides @RadRidesByTroy Blake Tomlinson Jim Jacobs Pete Chapouris Pete Eastwood Fay Butler Clay Cook Ron Covell @roncovell Scott Knight
Follow Bobby @waldenspeedshop on IG
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #hotrod #powerhammer #baileigh #baileigharmy #baileigh_industrial #yoder #metalshaping #pettingell #welding #bobbywalden #waldenspeedshop #pomona #californiaEp 27 | 90lbs of Mig Wire | US Navy Power Hammer Build w/ Dan TodorowSheet Metal Shaping2024-06-08 | On Episode 27 of the "Sheet Metal Shaping Podcast" we have Dan Todorow from Todorow Fabrication in Pennsylvania, USA
In this episode we chat about Dan's custom power hammer build stamped with US navy tags.
We also discuss:
- Being a solo operator in a metal + restoration shop - Restoration preferences - How he started his power hammer build - The lineage of power hammer ownership - Saving up cash for steel and additional materials - 131hrs in the pedestal build alone, 5000lbs, $7000 in steel, $1300 bending, +++ - How to lace a power hammer - Patterning a lower arm - Best and toughest parts of the build - Would he do it again?
Follow Dan @dantodorow on IG
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #hotrod #powerhammer #baileigh #baileigharmy #baileigh_industrial #yoder #metalshaping #pettingell #welding #dantodorow #todorowfabricationEp 26 | “As Nice As You Can Do It” | The Marcel Roadster w/ Luc De LeySheet Metal Shaping2024-04-25 | On Episode 26 of the "Sheet Metal Shaping Podcast" we have Luc De Ley from Marcel's Custom Metal in Norco, California
In this episode we chat about the history of Marcel's Custom Metal, past project's that have rolled out of their shop, and the Marcel Roadster
We also discuss: - Marcel De Ley started the shop in California, Belgian immigrant, sponsored to come to USA - Learning form his dad, older brother also involved in the early days - Took 12-15 years before Luc felt comfortable with his skills - It’s a tough job if you don’t enjoy it, also a great hobby - Difficult way to make a living, working per hour - The trade was “just a trade” back when Marcel started
- Brother was a great metal shaper, but preferred being a pilot - Luc buys out his brother in Marcels Custom Metal, goes on his own, Marcel helping for fun - Missing his dad as the shop evolved, now he works alone with the help of his wife Inger De Ley - Working to a specific standard and setting the bar high - Moving locations from commercial space to a work-from-home setting
- Doing the quiet work in the evenings, make noise during the day - Starting with a front and rear ¾ sketch, working from there - Starting with a rolling chassis w/ engine and drive train, building body around it - Design vs construction, where Luc focuses - Designing in your head vs on paper
- Making a buck with tubing and flat bar - Buck design, wire form vs wood: “I do not like wood” - Using ½” square tubing and 1”x .125 flat bar instead of round bar - Using the buck as a weld fixture with hood lines and trunk lines - Wireforms aren’t as accurate as a wooden buck, but provide more usability during the shaping process - “As long as it looks right, its ok, don’t take a tape measure to it”
- Working with California Metal Shaping over the years - Metal finishing is all about time, where do you want to stop - Doing it faster vs. do it nicer - Working with a metal finisher, Squeek White - Building beautiful cars with Rick Dore, Roger Berman, Chip Foose, Boyd Coddington, and many more ( @FooseDesignInc )
- Working in aluminum is preferred, due to weight - Staying away from repair work and focusing on coach building - Building the Marcel roadster - 3.5 years of build time, scratch build, all aluminum hand crafted body - LS3 V8, Borla Induction throttle body, winters quick change rear end, tremec 6 speed - 2360lbs, 480hp, 176” long, 66” wide, 94” wheelbase
- Realizing “what takes so long” to build a full car - What would he do differently with a scratch built car? - Ron Covell asks “Whats the hardest part about metal shaping?” @RonCovell - Winning 4 ridler cars and 11-12 AMBR winners
- Working in the shadows, behind the scenes - “Be like dad, and do this till I can’t”
For Lucs upcoming open house, follow him on Instagram
Follow Luc De Ley @marcelscustommetal on IG
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #hotrod #powerhammer #baileigh #baileigharmy #baileigh_industrial #yoder #metalshaping #pettingell #welding #lucdeley #marcels #marcelroadster #marcelscustommetalEp 25 | The Language of Aviation | Metal Shaping Aircraft Panels w/ William TromblaySheet Metal Shaping2024-04-07 | On Episode 25 of the "Sheet Metal Shaping Podcast" we have aircraft specialist William Tromblay
In this episode we chat about historical and modern aviation repair, and how that compares to automotive type metal shaping.
We also discuss: - 2nd most regulated industry in the world - How he got started - The progression of his family business from then to today - Speaking multiple industry languages - Restoration vs modern aviation construction - Is bigger better? Is smaller better?
- Common requests for metal shaping on aircraft - Dents and corrosion - Are all airplanes worth it to be restored? - Working from original blueprints to reproduce parts - Experimental category aircraft parts - Metallurgical analysis for replicating components - Grades of aircraft aluminum
- Tooling differences in aircraft shaping vs automotive panels - Working a reverse curve without making the edge too thin - Anticlastic curves and specialty tooling - Sharing information with other metal shapers - How to get started in aircraft restoration - Working with @Handbuilt1 Peter Tommasini and Fay Butler - Upcoming Metal Meet in 2024
Check out @Metalmeet on IG for this year’s Metal Meet workshop in Dennison MN hosted by Dan Pate @route56wingnut
Follow William @williamtromblay on IG and Facebook
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #hotrod #powerhammer #baileigh #baileigharmy #baileigh_industrial #yoder #metalshaping #pettingell #welding #williamtromblay #billtromblay #aircraftEp 24 | Carbon Fiber Comparison | Ferrari Replica’s in a 2 Car Garage w/ Brandon HegedusSheet Metal Shaping2024-03-12 | On Episode 23 of the "Sheet Metal Shaping Podcast" we have home build specialist Brandon Hegedus from Calgary, Alberta, Canada
In this episode we chat about reproducing classical Ferrari bodies with modern components, and a light touch on carbon fiber skins vs traditional metal coachwork.
We also discuss: - Learning how to build things as a kid - Started with hot rods, Model T - Selling 1 car to finance building the next - Ferrari replica build with Carbon Fiber - How he started with the 1962 Ferrari Sharknose project
- His model of building 1 car at a time instead of multiple projects - Modeling a historic vehicle through photographs - Touring a studio for inspiration and using closed cell foam to model the body skin - Working with a hot wire vs sanding the foam - 4.5 year Ferrari sharknose project, 2600 hours
- Recognizing constraints of a project (finance, parts, serviceability, etc) - Molds for laying carbon vs bucks for metal shaping - Selling the completed sharknose project to build the next one - Building a Ferrari 330P4 and a Ferrari 206 - Chassis first vs body first - Being creative with a 22x22 work space - 3d scanning an engine/ transmission to create an adaptor plate
Follow Brandon @howisthatstreetlegal on IG and @howisthatstreetlegal on Youtube
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #hotrod #powerhammer #baileigh #baileigharmy #baileigh_industrial #yoder #metalshaping #pettingell #welding #brandonhegedus #howisthatstreetlegalEp 23 | Reproducing Automotive History And Building New Tools w/ Pat BrubakerSheet Metal Shaping2024-03-09 | On Episode 23 of the "Sheet Metal Shaping Podcast" we have metal craftsman and business owner Pat Brubaker from Hastings, Nebraska
In this episode we chat about reproducing vintage bodies using the techniques he teaches, and constructing new english wheel/ sweep tooling for his customers.
We also discuss: - Working on an Aston Martin DBR1 and other hot rod projects - Scaling cars from a technical drawings + photography - 250 Hours of prep work to research the history, and proper shape of a car - Using fusion 360 for grid lines and full scale drawings - Using best judgment and artist interpretation during the creative process
- Using wood buck over a wire form, and how come - Sweeps and templates, either they fit, or they don’t - Preferred buck is a solid surface spray foam buck and building in hammer points - Making in-house sweeps with varying materials, 10”, 20” and 40” - Using equipment for the simplest thing it does the best
- Sorting out the how and why, before starting a project - Shrink vs stretch first, and why he does it this way - Financial cost of shrinking, vs stretching - Make a panel multiple ways and picking the way you like the best - She sheet metal doesn’t care, it does what it’s told
- Imperial wheeling machines, started by Kerry Pinkerton - Learning how to use an Imperial Wheeling Machine - Why people like cast iron English wheels
Follow Pat @imperial_wheeling_machines on IG
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #hotrod #powerhammer #baileigh #baileigharmy #baileigh_industrial #yoder #metalshaping #pettingell #welding #patbrubaker @imperialwheelingmachinesEp 22 | The Red Mist | Ferrari Inspired Art + Sculpture w/ Tony LauroSheet Metal Shaping2024-02-17 | On Episode 22 of the "Sheet Metal Shaping Podcast" we have artist, collector, and Ferrari aficionado Tony Lauro from Palm Beach, Florida
In this episode we chat about creating exotic automotive sculpture, and what happens behind the scenes to produce this type of work.
We also discuss: - Automotive design at the Cleveland institute of art - Collector of old school metal shaping videos - What better way to practice metal shaping than scaling down, ¼ scale projects - Mixing hobby, art, and business, with collectors
- The “Red Mist” romance at a concourse d’elegance - Talking about @cavallinoclassic Cavallino Classic car show in Florida - Working so hard, to have all this “stuff”, but having no time to use it - Getting hired by someone to finish a 1959 TR replica in a 13,400sf shop - Chip Foose “the biggest compliment is when someone knows you’ve modified the car, and can’t quite pinpoint what you’ve done. It’s so subtle, and makes the biggest difference”
- Creating models in CAD, and utilizing 3D scanning - Scanning an original 250 GTO - Standing out as an artist, and what is the market like for automotive sculpture? - Build art that inspires you, and the buyers will sense your passion - Push your boundaries on your art, some will fail and some will hit - 250GTO coffee table, and putting it on Bring a Trailer, and documenting the build
- It’s no longer boastful to showcase your work on social media. It’s the expectation. - Being isolated, as an artist, and how online communities help that
Follow Tony @hotshoestudios on IG and on youtube at @hotshoestudios
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #hotrod #powerhammer #baileigh #baileigharmy #baileigh_industrial #yoder #metalshaping #pettingell #welding #tonylauro #hotshoestudios #ferrariEp 21 | Will Figur Replace the English Wheel & Power Hammer? | 3D Shaping Technology w/ Rob IdaSheet Metal Shaping2024-02-11 | On Episode 21 of the "Sheet Metal Shaping Podcast" we have multi generational automotive craftsman Rob Ida from Rob Ida Concepts + Ida Automotive in New Jersey.
In this episode we chat about 3D metal shaping, what it means for the industry, and how it can be strategically used in the future.
We also discuss: - "Minimizing production runs", and on to the next - Being an artist vs businessman - Finding balance in this business and being kind to yourself - “Throw away hours” and reducing waste
- What is the Figur system of 3D metal shaping? - How does it work? - Is this going to replace skilled labor? - 3rd party forming so you don’t have to own the machine - Pushing this technology to the limit
- Using this for brightwork, trim, replacement panels - Balancing hourly labor cost vs using technology to be more competitive - Old school vs New Tech – Which is better? - Is this tech deflationary? - What can this machine not do? - What does this cost?
Follow Rob on IG at @rob_ida
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #hotrod #powerhammer #baileigh #baileigharmy #baileigh_industrial #yoder #metalshaping #pettingell #welding #robidaEp 20 | The Illusion of $70,000,000 Perfection | Forensic Study In Metal Shaping w/ Mark GerischSheet Metal Shaping2024-01-11 | On Episode 20 of the "Sheet Metal Shaping Podcast" we have 43 year metal shaping veteran, and teacher, Mark Gerisch from "The Academy Of The Art of Metal Shaping" in Green Bay, WI.
In this episode we chat about the illusion of "Perfect" $70,000,000 cars, and forensic study to recreate vehicles of significance.
We also discuss:
- Steps to metal shaping - Scaling images to recreate historic cars - 1967 275 NART spyder vs 550 Maranello - Online learning vs in person - How a student needs to shape their mindset in metalshaping
- Starting with the end result, working backwards - Shaping Polished vs Painted Parts - Graduating levels in metal shaping - What does a hammer do to a piece of metal when struck? - Hammer + Dolly techniques
- Unlearning techniques - Lancaster style shrinkers “unwinding” themselves - Work hardening and annealing - Talking about Shelby Cobra body bucks - Work to the buck, or work to the curb appeal
- The illusion of a perfect 70,000,000 car - Motion products are the top Ferrari restoration company in the world - Replicas vs original and what changes in fit + finish - Roadster Shop Chassis’ and their high quality
Follow us @sheetmetalshaping on instagram and Like/ Follow/ Share/ Subscribe to our channel for more great guests.
#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #hotrod #powerhammer #baileigh #baileigharmy #baileigh_industrial #yoder #metalshaping #pettingell #welding #markgerisch #aametalshapingEp 19 | 10x Concours d’Elegance Winner | A Casual Sit Down w/ Dave RemianSheet Metal Shaping2023-12-24 | On Episode 19 of the "Sheet Metal Shaping Podcast" we have long standing english wheel man Dave Remian of Toronto, Ontario Canada.
In this episode we chat about winning 10 Concours d'Elegance awards, and some past projects of the early 1900's era.
We also discuss: - Rebuilding Austin Healy cars and mentorship - Working with The Guild of Automotive Restorers - Rebuilding early 1900’s automotive history - Scottish mentorship descendent from Rolls Royce
- How the English wheel functions (Stretching) - Louvering in an english wheel - How many anvils do you actually need? - Using the pullmax with doming dies - Modern vs cast English wheels, quality
- Dave’s Brown and Boggs English wheel history - Time and budget for a Concourse winner - Remaking a historic car vs restoration, is it original? - Art deco motorcycle inspiration
Follow Dave on IG at @daveremian or info@remiaz.com
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #hotrod #powerhammer #baileigh #baileigharmy #baileigh_industrial #yoder #metalshaping #pettingell #welding #daveremian #remianzmetalshaping #remianzEp 18 | Copper Alloys | Architecture to Automotive Craftsmanship w/ Jeff ThompsonSheet Metal Shaping2023-12-07 | On Episode 18 of the "Sheet Metal Shaping Podcast" we have shop owner Jeff Thompson from Outshined Copper in Barrie, Ontario.
In this episode we chat in depth about the copper alloy as a raw material, and why it's just so beautiful to create with vs traditional metals like aluminum or steel.
We also discuss: - Architectural copper and automotive uses for the metal - Why 2 different “businesses” within copper metalworking - Why copper is a preferred material - Forming vs shaping copper - Copper workability vs aluminum/ steel
- Welding copper + filler rod choice - The price of material - Material thickness and alloy choice - Tooling for working with copper
- Buying a plannishing hammer from Karl @MakeItKustom - Hammering vs wheeling copper - Working with Mike at @cornfieldcustoms - Being inspired by others and competing against yourself
Follow Jeff at @outshinedmetal and @outshinedcopper on IG
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #hotrod #powerhammer #baileigh #baileigharmy #baileigh_industrial #yoder #metalshaping #pettingell #copper #outshinedcopper #outshinedmetal #weldingEp 17 | Entrepreneurship Secrets | The Inner Workings of Gas Monkey Garage w/ Richard RawlingsSheet Metal Shaping2023-11-30 | On Episode 17 of the "Sheet Metal Shaping Podcast" we have businessman, entrepreneur, car guy, and media personality, Mr. Richard Rawlings.
In this episode we chat in depth who is Richard the entrepreneur, and what does it really take to be successful in business.
We also discuss: - Who is Richard the entrepreneur - The SEMA show crunch time - Car guy or business guy? Or both? - How he started by flipping cars - Filing taxes at 12 years old - Removal of skilled trades in schools
- Scratch building a printing/ marketing company - Starting gas monkey @ 40 years old - The brand that is gas monkey garage - Fast growth vs cash flow - Alcohol, sauces, and merch
- Taking 8 years to get on TV, Making television shows - Going broke, twice. - Pre internet vs post internet - Starting in a household garage - Behind the scenes of the business - Cars are for content, to enhance the brand
- If it weren't for customers, employees and vendors, business would be easy - If you build it, they will come, if you do it right. - Do you want to have a simple life, or do you want to make money? - Talking about @FooseDesignInc Chip Foose - When you hit your $ number, it always seems to move, for a true entrepreneur
- 1% of ppl succeed at this stuff - He loves the service business, but 1 person can only do so much service - Being a service provider, how many cars can you make per year as a solo shop owner - Net Margin on 1m in auto business - Building a sellable entity in multiple verticals
Follow Richard @GasMonkeyGarage , and www.gasmonkeygarage.com, and @rrrawlings / @ gasmonkeygarage on IG
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #hotrod #powerhammer #baileigh #baileigharmy #baileigh_industrial #yoder #metalshaping #pettingell #gasmonkeygarage #gasmonkey #richardrawlingsEp 16 | Plan Your Next Steps | Automotive Coachbuilding Lessons w/ Peter TommasiniSheet Metal Shaping2023-11-23 | On Episode 16 of the "Sheet Metal Shaping Podcast" we have Peter Tommasini, an Australian coach builder and 54 year veteran of the trade.
In this episode we chat in depth about common "how-to's" of panel beating in the automotive field and why they are important.
We also discuss:
- Being born in Venice Italy - Moving to Australia in the 1970’s - Coachbuilding vs smash repair - Spending money on coachbuilt cars vs cars of low value - Austalian vs Canadian Vs USA economy / Interest rates
- How to build a roof skin, where to start - Largest panel size that can be wheeled? - It’s how you hold the panel that makes the shape - Where to place welds, oxy welding - Controlling weld distortion
- Planning your welds and shaping in advance - Biggest issues students face today - Recognizing stress in a panel - Blending techniques from various countries - Ask a question, then practice
- Options for patterning an existing piece - Shrinking vs stretching, speed - MDF and aluminum profile gauges - Symmetry of a classic cars (often) isn’t as it appears - What’s missing in the industry today? - If you have the passion, the patience will come
Follow Peter on youtube at @Handbuilt1 , and www.handbuilt.net.au
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #hotrod #powerhammer #baileigh #baileigharmy #baileigh_industrial #yoder #metalshaping #pettingell #petertommasini #handbuiltSmash repair vs metal shaping sneek peek w/ Peter Tommasini, podcast episode goes live Nov 23rdSheet Metal Shaping2023-11-21 | The Sheetmetal Shaping Podcast w/ @Peter Tommasini goes live this Thursday Nov 23, 2023Ep 15 | Excellence Was Expected | Behind The Scenes Of A Modern Day Coachbuilder w/ Chris RungeSheet Metal Shaping2023-11-17 | On Episode 15 of the "Sheet Metal Shaping Podcast" we have Chris Runge, a modern day coachbuilder from Rural Minnesota, USA
In this episode we chat about his rise to excellence in the coachbuilding field, and what it takes to successfully remain in this craft today.
We also discuss: How he got started The progression of his coach built cars Automotive design “Excellence was expected” Barns full of Porsche parts and metal shaping tools Going to the junkyard as a kid Working in multiple skilled trades disciplines Formal training vs non formal training
Inspirations of an era, and designs of that time Maintaining motivation “Art in motion, and timeless by design” Evolution of artistry, and personal growth
Being on Jay Leno as a modern day coach builder Classic Driver Magazine raising awareness about Chris Drawing awareness to the craft
Do computers kill the soul or a project? How many hours in a hand built Runge car? Repurposing skills
Buck building – wood vs aluminum and the perks of each Carpet under an English wheel? Building a new workshop Furniture vs automotive fabrication Chris the artist vs chris the businessman, balancing act Customers are buying a piece of the story, and a piece of the art
Follow Chris @christopher_runge on IG, @RUNGECARS on youtube, and rungecars.com
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #hotrod #powerhammer #baileigh #baileigharmy #baileigh_industrial #yoder #metalshaping #pettingell #rungeRS #chrisrungeEp 14 Building a Ferrari 625 TRC and Jaguar C Type w/ Harry DeetlefsSheet Metal Shaping2023-11-09 | On Episode 14 of the "Sheet Metal Shaping Podcast" we have Harry Deetlefs, a coach builder from Johannesburg, South Africa
In this episode we chat about how he has completed 2 beautiful projects: a Ferrari 625 TRC tribute, and a Jaguar C type tribute.
We also discuss: - How he got started - Learning all over the world - Evolution of the automobile - Cars of the vintage era have a soul
- Opening a shop with an English wheels and hand tools - Where his services start and stop - There are no 100% perfect cars out there - Shrinking in a stump - Working with Aluminum and the English wheel
- Jaguar C type Build and the extreme attention to detail - Making paper patterns + flexible shape pattern
- Hand crafting the Ferrari 625 TRC - Making the body, and the modified chassis - Researching the car for hundreds of hours - Scaling up a historic car 1.5x - 4000-5000hrs of build time
Follow Harry @englishwheelfabrication on Instagram/ Facebook
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #hotrod #powerhammer #baileigh #baileigharmy #baileigh_industrial #yoder #harrydeetlefs #coupesimone #metalshaping #iconicrodncustom #pettingell #ferrari625trc #ferrariEp 13 The Coupe Simone + Ferrari 250 GTO Build w/ Greg Martin (Iconic Rod & Custom)Sheet Metal Shaping2023-11-03 | On Episode 13 of the "Sheet Metal Shaping Podcast" we have Greg Martin, a shop owner and spec car builder from Pennsylvania USA.
In this episode we chat about how he has taken on 2 beautiful projects: a Ferrari 250 GTO tribute car body, and an end to end build of the romanticized tribute Duesenberg named "Coupe Simone".
We also discuss: - How he got started in the industry - The creative vs bread and butter industries - The Ferrari 250 GTO build early beginnings - Building the buck, wire vs wood - Being “At School” every day, self taught - How many hours does it take to build a Ferrari body? - The legend of “Coupe Simone” - Linking Dusenberg and Coupe Simone - 3D Modeling with scanning and wide format plotting - Building a buck from 3D plotting - 450 Hours in the buck construction - Spec builds, without a buyer upfront - Who’s the buyer? - How many hours end to end to build this car?
Follow Greg @iconicrodcustom2159 on youtube, and @iconicrodncustom on Instagram/ Facebook
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #hotrod #powerhammer #baileigh #baileigharmy #baileigh_industrial #yoder #gregmartin #coupesimone #metalshaping #iconicrodncustom #pettingell #Ferrari250gto #ferrariEp 12 The Scratch Built 13,000LB Yoder Power Hammer w/ Brian HainerSheet Metal Shaping2023-10-09 | On Episode 12 of the "Sheet Metal Shaping Podcast" we have Brian Hainer, a metal craftsman from the shores of Connecticut, USA.
In this episode we chat about how he hand built a replica Yoder power hammer, and all of the the nitty gritty details involved to do so.
We also discuss:
- How he got started - How furniture started helping him to see shapes - The pre internet generation, locating tools - The aristrocaracy and secrecy around this craft - 2” thick base plate, 2” thick arms, 13 000lbs fabricated power hammer - The importance of wood on a power hammer - Making his own hammer dies, S7 heat treated - True radius vs flats on a power hammer die - 5 degree dovetail and 1 degree wedge as per original Yoder - Would he change anything after it was done? - What it cost, and how many hours to build it vs today’s prices? - Dual purpose mast with an English wheel - The 6 minute door skin
Follow Brian @metalshaper on youtube
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #hotrod #powerhammer #baileigh #baileigharmy #baileigh_industrial #yoder #brianhainer #metalshaping #pettingellEp 11 Freelance Coachbuilding and the James Bond of Metal Shaping w/ Ludovid RollandSheet Metal Shaping2023-09-28 | On Episode 11 of the "Sheet Metal Shaping Podcast" we have Ludovic Rolland of Ludo Metal Arts in France.
In this episode we chat about being a freelance coachbuilder for multiple high end shops, and being the "James Bond" of metal shaping.
We also discuss:
- What is a freelance coachbuilder - Getting started in the industry/ developing base skills - Soap box race cars - What a pile of metal looks like to a metal shaper vs every day person - Learning by trial and error, and from others - Comparing shaping techniques to other countries - Travelling from shop to shop vs. staying in 1 location - Acquiring knowledge, experience, and contacts in the trade - Making bets with co-workers - Travelling with an English wheel (The "Trolly") - Skills required to operate a business vs being an artist - Working on Italian cars, Bertone cars, Rolls Royce, and many others - The toughest part, is at the end of a project
Follow Ludo @ludometalarts on IG
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #hotrod #powerhammer #baileigh #baileigharmy #baileigh_industrial #ludo #jamesbond #ludometalarts #ludovicrolland #trollywheelEp 10 The Aston Martin Build Progress, Tooling, and Metal Sculpture with Ryan BauerSheet Metal Shaping2023-09-24 | On Episode 10 of the "Sheet Metal Shaping Podcast" we have Ryan Bauer of Resurrected Metal Shaping in Australia
In this episode we chat about Ryan's Aston Martin build, workshop tool talk, and metal sculpture.
We also discuss:
- Working with Bentley / Jaguar - Techniques of classically trained builders vs modern times - Starting without fancy tools - Working alone vs working with others - Aston Martin build / 3D Scanning - How to tell if a shape is “off…” - Buck building - Shrinking with an Eckold vs Pullmax - Shop Layout - Metal Sculpture
Follow Ryan @resurrected_metalshaping on Instagram
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #hotrod #powerhammer #baileigh #baileigharmy #baileigh_industrial #ryanbauer #resurrectedmetalshapingEp 09 The Multi-Faceted Skills of A Coach Builder, with Clark Gillie CustomsSheet Metal Shaping2023-09-14 | On Episode 9 of the "Sheet Metal Shaping Podcast" we have Clark Gillie of Clark Gillie Customs in Colorado USA.
In this episode we discuss the multi faceted skills of a coach builder, and what it truly takes to "Get It Right" in restoration, prototyping, and custom metal work.
We also discuss:
- How he got started - Being excited to go to work, fulfillment - Business owner vs being an artist - So many ways to get something done - Working with Wray at @proshaper - Chopping tops, and proportions, as a coach builder - Wanting Rick Dore on the podcast - Productivity of English wheel vs power hammer - Difference between hot rods, and coach building - Remaining Teachable
Follow Clark @Clarkgilliecustoms on IG
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #dragster #hotrod #baileigh #baileigharmy #baileigh_industrial @clarkgilliecustomsEp 08 Designing + Manufacturing Baileigh/ RMD Equipment With Chris RuschSheet Metal Shaping2023-09-07 | On Episode 8 of the "Sheet Metal Shaping Podcast" we have Chris Rusch of Rusch Machine and Design/ Baileigh
In this episode we discuss the early origins of Chris's coach building/ metal working designs, and how that merged into the Baileigh Industrial brand.
We also discuss:
- Starting Rusch Machine and Design (RMD) - Selling RMD to Baileigh Industrial - Being a serial Entrepreneur - Learning from Mark Gerisch - Early design phases of RMD/ Baileigh equipment - Filling voids in the industry - Why build the Baileigh MH-19 - Legacy equipment (Yoder, Pettingell, Pullmax, etc) vs modern RMD shop equipment - The dupont linkage and elegant castings of the past - Side project of a Ferrari 250 GTO - Vyper Chairs
Follow Chris at @chris_rusch on Instagram
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #ferrari #dragster #hotrod #chrisrusch #baileigh #baileigharmy #baileigh_industrial #vyperchairsEp 07 Building a 1965 Ferrari 275 GTB Competition Coupe Tribute Car w/ Kyle YocumSheet Metal Shaping2023-08-31 | On Episode 7 of the "Sheet Metal Shaping Podcast" we have Kyle Yocum of Yocum's Signature Hotrods
In this Audio-only episode, we cover hand sculpting a 1965 Ferrari 275 GTB Competition Coupe tribute car.
We also discuss:
- Getting started building a car like this w/ 3D Scans - Plywood buck building on a 1995 Ferrari V12 Chassis - Starting with a windshield, and building around it. - Working and welding .063" 3003 Aluminum - Wood or wireform buck preference - The hardest part of scratch building cars - How long does it take? - Power hammer and english wheel tool talk - Old machines and new machines, which is better?
Follow Kyle at yocumsrodshop.com or on instagram and youtube@YocumsRodShop
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #ferrari #dragster #hotrod #kyleyocum #yocumssignaturerodshop #baileigh #baileigharmy #baileigh_industrialEp 05 The Sheet Metal Shaping Podcast w/ Nick Cologero of Catskill Mountain CustomsSheet Metal Shaping2023-08-17 | On Episode 5 of the "Sheet Metal Shaping Podcast" we have New York State sheet metal shaper Nick Cologero of Catskill Mountain Customs
In the episode, Nick and I joke about “Behind the scenes” of running a podcast, and how sometimes they don’t go as planned. As such, the Wifi signal had a few spotty moments but nothing that wasn’t overcome to complete the time that we spent together.
We also discuss:
- Industry Myths - How to make motorcycle gas tanks - Material Selection (aluminum vs steel vs stainless) - Metal Finishing a polished sheet metal component - Building motorcycle fairings, and working from photos - Spending time on a buck vs free forming - Pattern making and making mirrored parts - The importance of Prep work - How to work efficiently in a 2 car Garage - Skills vs Equipment, is it worth spending the money?
Follow Nick @catskill_mtn_customs on Instagram
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #nickcologero #catskillmtncustomsEp 04 The Sheet Metal Shaping Podcast w/ Dave Ryan (@toirpanelsmasher)Sheet Metal Shaping2023-08-09 | On Episode 4 of the "Sheet Metal Shaping Podcast" we have 40 Year coach building veteran Dave Ryan, @Toirpanelsmasher on IG
Dave was kind enough to record an episode with us from his trailer on a private horse farm in Western Canada. At this rural property, he was hired by an individual to scratch build a very specific vehicle, which we talk about in the show. As such, the Wifi signal had a few spotty moments but nothing that wasn’t overcome to complete the hour that we spent together.
We discuss:
- Apprenticeships - Cost of a power hammer years ago - Coach building post-war era and how industry evolved - 13,000 hours working on Cord aero-coup for a private client, $800 000 project - Placing value on projects vs being a creative - Making a fender for a 32 ford - Templating with plastic or paper, like Fay Butler - Shrinking with a power hammer or pullmax - How long to make a front fender, and working on a Talbot Lago - English wheel vs power hammer vs Speed - Working w/ Mike Kleeve in Carolina, and what can be learnt after 40+ years of shaping - Working to a buck, and how close is close enough - Working with Radius Gauges
Follow Dave @toirpanelsmasher Instagram
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #daveryan @toirpanelsmasherEp 03 The Sheet Metal Shaping Podcast w/ Karl Fisher (@Makeitkustom / Japhands Kustoms)Sheet Metal Shaping2023-08-03 | On Episode 2 of the "Sheet Metal Shaping Podcast" we have Karl Fisher, Owner of Japhands Customs and revered Youtuber @makeitkustom
We discuss:
- Coach Building vs Hot Rods - Power hammer vs english wheel vs the benefits of each - Growing a youtube channel as a business - Traveling to Australia to meet other coach builders - The importance of patterning, and patch panels - Wire Forms and using them to make custom car panels - The Lincoln Zephyr project, and why the body lines are so tricky to replicate - How close should you get a panel to fit - Custom made Pull Max style machine from scrap parts - Living in a throw away society vs scratch-built
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcast #japhandskustoms #karlfisher #makeitkustomWelcome to the Sheet Metal Shaping Podcast!Sheet Metal Shaping2023-07-28 | Welcome to the Sheet Metal Shaping Podcast!
Here's a quick intro video about the show where we discuss the pursuit of sheet metal shaping education through traditional coach building techniques.
Catch you on the next episode!
#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcastEp 02 The Sheet Metal Shaping Podcast w/ Ayden Hunt (Bespoke Coach Works)Sheet Metal Shaping2023-07-28 | On Episode 2 of the "Sheet Metal Shaping Podcast" we have Ayden Hunt, owner of Bespoke Coach Works
We discuss:
- The industry of coach building - Custom Rolls Royce and Auburn bodies - Power hammer vs english wheel vs the benefits of each - The importance of highlight lines in a panel - The importance of paper patterns, and how he uses them - Welding and metal finishing, the biggest time sucker - How close should you get a panel to fit - The importance and history of design
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#englishwheel #sheetmetalshaping #powerhammer #coachbuilt #builtnotbought #handmade #pullmax #podcastEp 01 The Sheet Metal Shaping Podcast w/ Mike Wagner (Cornfield Customs); Timelines, Tools and TipsSheet Metal Shaping2023-07-19 | On Episode 1 of the "Sheet Metal Shaping Podcast" we have Mike Wagner, owner of Cornfield Customs.
We discuss:
- Industry History - Pricing and Timelines - Power hammer vs english wheel - Shop Tooling - Welding and metal finishing - How close should you get a panel - The importance of design
Follow Mike at @cornfieldcustoms on Instagram
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