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WrennMetallWerks
Samba Member
Joined: December 06, 2007
Posts: 2666
Location: Rescue ca
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TRS63
Samba Member
Joined: December 17, 2017
Posts: 1000
Location: Stuttgart - Germany
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WrennMetallWerks
Samba Member
Joined: December 06, 2007
Posts: 2666
Location: Rescue ca
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metz
Samba Member
Joined: March 31, 2005
Posts: 280
Location: Norway
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 Posted: Thu Jan 18, 2024 12:22 am Post subject: Re: 59 Karmann Kab |
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Digging these photo dumps. Great work!
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68 panel
64 ghia coupe |
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calexican
Samba Member
Joined: June 11, 2008
Posts: 730
Location: El Paso, TX
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| Posted: Thu Jan 18, 2024 8:24 am Post subject: Re: 59 Karmann Kab |
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| What a beautiful legacy. I have to say your photos are really great. I can’t seem to get enough of seeing the anatomy of these beautifully designed cars, and the way you include some of the other cars in the shop, the Porsche….you can see the lineage….so cool….maybe someday for me, I’ve been dreaming about it for over a decade… keep up the good work! |
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WrennMetallWerks
Samba Member
Joined: December 06, 2007
Posts: 2666
Location: Rescue ca
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Loren
Samba Member
Joined: January 10, 2004
Posts: 1702
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| Posted: Thu Jan 18, 2024 1:51 pm Post subject: Re: 59 Karmann Kab |
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Wish my Ghia cab had been as nice as this one to start with. You will have this knocked out in no time.  |
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WrennMetallWerks
Samba Member
Joined: December 06, 2007
Posts: 2666
Location: Rescue ca
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WrennMetallWerks
Samba Member
Joined: December 06, 2007
Posts: 2666
Location: Rescue ca
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WrennMetallWerks
Samba Member
Joined: December 06, 2007
Posts: 2666
Location: Rescue ca
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sputnick60
Samba Moderator
Joined: July 22, 2007
Posts: 3918
Location: In Molinya Orbit
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| Posted: Fri Jan 19, 2024 1:46 am Post subject: Re: 59 Karmann Kab |
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| WrennMetallWerks wrote: |
| I had given it some thought and realized some folks maybe interested in the explanations of the metal shaping process I’m posting pix of? I would be happy to take the time to freely give the knowledge that was so generously passed on to me from my metal mentors. ⚒☑️👀🕊🤍 |
Yes. Of course we'd be interested. Please do
Nicholas
_________________
'66 Karmann Ghia Cabriolet...
'65 Porsche 356C Coupe...
2005 Mecedes Benz C180 Kompressor Estate
Stop dead photo links! Post your photos to The Samba Gallery! |
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VeloMikey
Samba Member
Joined: March 19, 2012
Posts: 656
Location: So Cal
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| Posted: Fri Jan 19, 2024 7:17 am Post subject: Re: 59 Karmann Kab |
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I will start...
What is "metal finishing"?
Is the green tape thing a pattern? Why isn't it made of cardboard or metal?
Why are there what look like relief marks on the pattern but they are not cut out?
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'58 Ghia 2387cc with a Berg / Folts 5 Speed
Ghia Build Thread https://www.thesamba.com/vw/forum/viewtopic.php?t=768748 |
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WrennMetallWerks
Samba Member
Joined: December 06, 2007
Posts: 2666
Location: Rescue ca
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WrennMetallWerks
Samba Member
Joined: December 06, 2007
Posts: 2666
Location: Rescue ca
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WrennMetallWerks
Samba Member
Joined: December 06, 2007
Posts: 2666
Location: Rescue ca
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| Posted: Fri Jan 19, 2024 10:04 pm Post subject: Re: 59 Karmann Kab |
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| VeloMikey wrote: |
I will start...
What is "metal finishing"?
Is the green tape thing a pattern? Why isn't it made of cardboard or metal?
Why are there what look like relief marks on the pattern but they are not cut out? |
Hey Mr Mike. I love everything about the way you approached this. To me
this is what the forums are all bout. All of us sharing, learning , and engaging.
I will be looking for folks to reach out the way you did and ask about things that interest them. Thanks for that Mr Mike , very cool. Great questions to by the way.
So metal finishing has many forms….
Particularly in this situation it was the final steps after the panel is welded in and it started with grinding the welds down about 80 percent using the edge of a small cutting blade once that was done I use 2” 36 grit roloc disc on and angle sander to take the welds as flush as I can get them without taking away metal on the surrounding metals that I just joined together. After that I switch to a 3” 60 grit roloc disc to lightly blend the welds and the materials, being very careful to take off very little more metal then necessary. Once that’s done I add lay out ink to the panel to use as a guide coat and then using a vixen file I file the panels and what litt is left of the welds to just about as level as it can bel, the lay out ink tells me where and if their are highs and lows that need to be addressed to reach the desired finish I’m after. I do what’s necessary to improve on the panel one last time if i feels it’s necessary , then the real “finish “ starts. I begin with a DA sander with 80 grit sand paper and then change to 100 grit once everything is blended to my satisfaction then I use another DA with a red Scotch Brite to get the final result you see in my photos. All of this takes quite some but I’m getting faster at every year.
Yes Mike , the green tape is a pattern. I made it about eight years ago , the reason it is tape is because if you use it in a certain way directly on a good panel it will keep the shape of said panel when removed . The trick is to do at least three layers in opposite directions. When this particular pattern was made it was made to shape a panel I needed for a project I had at the time. The relief cuts you see dictate where I will need to shrink the panel to get the shape I want. When the pattern of tape is done on the good panel I was trying to duplicate I pulled it off the car once I made the cuts it lays out flat so I could transfer it to metal.
Another popular way to do this is with butcher paper, when you fold the tucks of the paper to contour and the panel it tells you almost exactly where to shrink, the paper is a cheap and simple way to make a paper for metal shaping.
Great questions man. I appreciate the engagement 🤩👊
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⚒ Believe In The Power Of Positive Thinking ⚒
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https://music.youtube.com/watch?v=_NzUyyVexAE&feature=share
https://music.youtube.com/watch?v=UI8yUrIWS7E&feature=share |
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WrennMetallWerks
Samba Member
Joined: December 06, 2007
Posts: 2666
Location: Rescue ca
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TRS63
Samba Member
Joined: December 17, 2017
Posts: 1000
Location: Stuttgart - Germany
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WrennMetallWerks
Samba Member
Joined: December 06, 2007
Posts: 2666
Location: Rescue ca
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DariuszPlich
Samba Member
Joined: July 06, 2017
Posts: 60
Location: Polska
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| Posted: Wed Jan 24, 2024 12:08 pm Post subject: Re: 59 Karmann Kab |
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I see a professional approach and execution. Great, I'm waiting for more. Maybe someday I'll be able to do that too  ) |
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WrennMetallWerks
Samba Member
Joined: December 06, 2007
Posts: 2666
Location: Rescue ca
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