19. This time the work on MG TC front wing has come to an end

The work that remains is the front end. More intricate shaped details with more complex fitment than those in the rear end. During the work the use of a simple but important fixture is demonstrated. And the last Eckold tool is introduced.

The reason behind some repairs on the wing has been fatigue cracks. In Image 1 such is seen, vibrations are an important factor behind such problems.

Image 1 Rust and vibrations create cracks with advanced age.

This part of the wing is shaped after the chassis, which means that it drops down forward. Easy to copy, the work started with a strip of sheet bent in the folding machine, Image 2. When the profile was correct the part was stretched in the Kraftformer, Image 3. Note that the stop was used.

Image 2 Making of the new panel starts in the folding machine.
Image3 Shaping the new panel by stretching in the Kraftformer. Note the use of the stop.

The shape was controlled against the wing, Image 4. When it was found satisfying a fixture was created. The purpose for the fixture was to keep the area in position during the coming work. The fixture was temporarily attached to the wing by M5 screws. Later the screw-holes was closed by welding.

Image 4 The shape is controlled against the wing. Note the fixture holding the edge of the wing in correct position during the work.

The old part of the wing was removed and the new part was fitted, Image 5.

Image 5 The new panel dot welded.

Finally the work with repair of front edge was initiated, to a beginning with making a template Image 6. The ends of the template are marked with a marking pen. This is extra material for the shaping work in the swage machine and will eventually be removed. At the ends of the shaping in the swaging machine it is often difficult to get perfect results. The surplus material in the ends is later removed before the fitting.

Image 6 A t template hold by magnetos is made.

The shape of the template is transferred to the sheet with help of a compass, Image 7. With the use of a compass it is possible to add the material for wrapping around the wire.

Image 7 The material for wrapping around the wire, in this case 9 millimeter, is added to the template contour using a compass.

With the sheet cut clean some slight shaping in the air planishing hammer the right double curvature was created, Image 8, before the shaping of the edge for the wiring.

Image 8 Creating a double curvature in the air planishing hammer.

With the new part shaped the fitting began by clamping the sheet to the wing, Image 9, followed by marking out the margins and careful dismantling the old sheet. Image 10 show the new panel welded to the wing and with the edge wrapped around the wire. After leadfilling the wing was ready for deliver to the owner.

Image 9 After shaping of the outer edge in the swaging machine the fit is controlled.
Image 10 Only a thin layer of lead was needed after welding and careful grinding.

The time has come to the last tool in the Eckold series, the tool-holder, Image 11. This equipment brings the Kraftformer close to the Pullmax machine in function. As the name tool holder suggest it must be used together with a tool created for a specific purpose. The tool in Image 12 is a such used for making floor panels for an Alfa-Romeo from the late 50`s, Image 13

Image 11 The tool holder.
Image 12 A tool with drawing.
Image 13 A floor panel was made and fitted to an Alfa-Romeo 200 Berlina.

The tool in Image 12 is cut with water from a 20 mm thick sheet of steel, see the drawing in the picture. Note that the 110x110 mm sheet is cut at the midline creating a female and she-male half. In this case the cutting process removed as much material as the thickness as the sheet used in the floor panel, 0.9 mm.

In Image 14 the tool is attached to the machine with the tool holder and in Image 15 and the film the shaping process is demonstrated.

Image 14 The tool in Image 12 attached in the tool holder. To the extreme right the stop.
Image 15 Creating a groove in a panel.

To be continued...

Panel Beating Doctor Bengt Blad

At this point in my life when I was about three quarters through the medical schooI I discovered the English wheel and the Eckold machine, and, one thing leading to another - no more time for med school.

More about the book

This book, with around 1,500 pages of reader-friendly text and about as many illustrations, is a summary of 40 years of working with vintage, collectors' and racing cars.

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