Cool Tool No1: make corrugated iron for scale models and dioramas

I've got an excellent new tool that I am using to make corrugated iron panels for my latest diorama. Normally I'm all for making it yourself, not purchasing a one-use tool, but this is such a brilliant piece of engineering that I can't resist it. Plus, it saves me money as I can now make all the corrugated metal panels I want!
You can purchase the Brunel Hobbies corrugated iron maker here:
www.brunelhobbies.com.au/ironm...
(BTW, I get no commission, this is not a paid promotion)
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[@hanleysoloway7965]

I found a shelf in the fridge at work that has perfect ridges for 1:64 corrugations, don't tell work but it's not in the fridge anymore.

[@DavesModelWorkshop]

Heh heh - perfect!

[@dougsundseth6904]

A couple of comments: In the US, large containers of drink powders (lemonade and the like) and smaller containers of nuts are "sealed for your protection" with a heavy foil. This stuff works pretty well for embossing (rivets or corrugated iron). Limited in size, of course. You might also look for heavy-duty aluminum foil, often used here for barbecueing. It's entirely possible to make similar embossing jigs using dowel or wire (depending on scale) attached to a flat substrate like MDF. As long as you use a two-part jig and press down rather than dragging across, you can get nice curves rather than edged forms.

[@DavesModelWorkshop]

Hi Doug, thanks for those points. Hmmm, yes, we also have those disposable aluminium BBQ trays here in Aus, that might be more workable as well. I considered building my own jig, with styrene rod - but in the end for the $20 pricetag I got lazy and decided to buy this! (Plus it looks a lot slicker than anythingI could have jerry-rigged together!) Dave

[@dougsundseth6904]

@@DavesModelWorkshop I wasn't actually talking about the trays, though they might work, but rather about rolls of heavy-duty aluminum foil. One brand name that I've seen is Reynolds Pitmaster's Choice Aluminum Foil, but there are others. From what I've seen, they seem to run about twice the thickness of the usual kitchen foils. I understand about just buying the tool; it's definitely easier. But $20 seems like a lot to me. (I'm probably spoiled by US hobby prices, which seem quite a bit lower than the same things in Oz in many cases.)

[@mookins45]

@@dougsundseth6904 'Greek Gods' yogurt containers have a heavy foil for sealing under the lid...

[@kerryadams8922]

Looks so realistic . Great video update THANKS for another great technique tip. THANKS Kerry

[@ChrisSmith-nm8gb]

That is so neat. Looks great.

[@allanstott6999]

Thanks for the tip. I'll be ordering one soon.

[@wudbcarmodeller2713]

Great product and a great video. Thank you.

[@MikeCindyWhite]

Very cool bud, thanks for sharing!

[@AbatNZ]

Very cool Dave. Enjoying your dioramas very much.

[@DavesModelWorkshop]

Thanks Alastair - it's different ground for me, but damn I am enjoying it. Cheers mate.

[@wwkdiecastmore5647]

Thanks for sharing, really nice product!...Bill

[@soonersteve3733]

I have some scale tin roofing in 1/35. I mounted one to a block of wood and did the same to a second piece. I marked the blocks of wood so the two pieces would align with each other. Took heavy duty foil and it worked but still too flimsy for my liking. My best result came from using the aluminum tape used on air conditioning duct work. Because the tape has adhesive on on side, I cut the tape into the lengths I wanted and just applied them to a regular sheet of copier paper. This added much more strength to each piece. I would then put the trimmed sheet between my two wood blocks and with a little pressure rub until the corrugation was complete. I would paint each and they were much easier to work with and bend to any shape I wanted. Oh by the way Dave I use my home made rust that I learned from your channel to weather my finished roof.

[@morrieskustoms6430]

Yeah nice, i use a Fiskas paper crimper and some cooking trays for 1/24 works perfect

[@lookinglassdca9174]

Man o man great review as always just ordered.

[@bigcharliesmodelgarage296]

That is a cool tool Dave thanks for sharing.

[@DavesModelWorkshop]

Cheers Big Charlie :)

[@backpacker3421]

using a rotary cutter will help prevent the tearing when you cut because it won't pull. their fairly cheap and work well on any sort of fabric or other thin material like that

[@garyparker2969]

Pretty Cooolll Stuff there Dave, thanks for sharing n God Bless All

[@DavesModelWorkshop]

Thanks as always Gary, look after yourself sir. Dave

[@bilgerat7694]

Bloody awesome mate looks good

[@DavesModelWorkshop]

Thanks Bilge Rat!

[@Fourwheeljive]

Cool tool!

[@fx1c333]

Xl turkey foil oven tray best. thin curls up using plastic part rubbing two bits of plastic together = static and the foil does conduct electric.

[@marvelingabout8240]

Brilliant because of the simplicity. It is basically an impression maker. Have you tried folding the foil for twice the thickness?

[@alanwinkley8811]

How cool is that new tool. Thanks for sharing this with us Dave. If I could make one request, how about a video on painting those rusty corrugated sheets.

[@DavesModelWorkshop]

Alan, you got it. I'm in the process of making it right now! Check this space next week. Cheers, Dave

[@amraceway]

I find the quickest way to simulate rust is to spray the object with satin black, I use Export paint from Super cheap auto. Next I use acyclic burnt ochre with a really watery brush straight over the black. Sometimes I go over it with a super thin coat of black again. Quick,cheap,easy and effective.

[@graemebrumfitt6668]

If you buy garlic past or tomato puree in tubes the ali foil is pretty good for all sorts of things, I will try using some for this! TFS 'thanks for sharing' GB :)

[@charleshenderson9578]

Dave you still can used Aluminum foil. They do have some are heavy duty. Some are used for out door grilling. I know, i used them from time.

[@andrewshaw8396]

Good bit of kit by the looks. Certainly a nice result. The metal foil from a takeaway carton would be more substantial I reckon. Cheers.

[@DavesModelWorkshop]

Ahh, that's a good idea - thanks Andrew.

[@lancecaldwell3874]

Looks very good and too scale. Great to see an Australian product that scratch builders need for the tool box. Having it so close to scale thickness also lends itself too damage that would be easy to replicate. Thanks for sharing.

[@DavesModelWorkshop]

The scale thickness is what I like about it, but damn it is flimsy!

[@lancecaldwell3874]

@@DavesModelWorkshop all you need now is framing like the real thing! And poking holes for the rivets. Lol...

[@graemetaylor202]

Best to use HEAVY DUTY foil as is keeps it's shape better and does not tear as easily. For those in Australia, try the Jumbuck BBQ Heavy Duty Foil, 40cm wide and 30m long, $10 at Bunnings, it will give you a lifetime supply.

[@robertboyd321]

Yep its a great little tool, and if you want real strong corrugated sheets go to the local store & buy a couple of those large BBQ drip trays. They have a flat bottom about the size on an A4 sheet & using this tool you can make many sheets of strong corrugated roof tin out of each one. The throw away baking dishes are the same thickness but they are even bigger in size. Cheap as chips too & once you put in the corrugations your fake roof iron is extremely strong . You have to press down on the tool a little harder but it's still very easy to do. Give it a try.

[@DavesModelWorkshop]

Hi Robert, thanks for the tip. Yes, a while ago I discovered the wonder of BBQ trays as well! They are much more durable, I agree. But thanks for the tip - I 100% agree with you - Dave

[@BALD8BIL]

This is a pretty cool tool I bet you could probably use the heavy duty aluminum foil and I do know in the US a lot of us use aluminum cans but I would like to thank you for sharing this pretty cool tool with us

[@DavesModelWorkshop]

I'm going to keep an eye out everywhere I go now for thicker aluminium!

[@DJC995]

Many years i cut up baked bean cans for corrugated roofing it worked but not the best idea that tool look's a lot better and safer Than's

[@DavesModelWorkshop]

That's a cool idea though Darran. There's definitely something in that.

[@DJC995]

@@DavesModelWorkshop Hi Dave Thank's for the reply

[@adrianforest4511]

This looks great, but I'm really stuck on trying to work out ways to make it less fragile. I like the suggestion of a backing sheet that several folks have made, with some kind of hard-drying substance to hold the shape. Would a clearcoat over the top before painting/weathering be worth trying too?

[@kevinbrister8801]

Try a soda can!

[@axtmann]

That looks amazing, and it's such a simple tool! The rust perforations are extremely convincing. This might be overkill but perhaps a coating of PVA glue or acrylic floor polish (Future etc) on the reverse side of the panel can stiffen them and make them a little more resilient against handling.

[@DavesModelWorkshop]

I agree, I think it needs something like that to give it more strength. Sooner Steve added a comment which might work well, using air conditioning aluminium tape - I'm going to explore that.

[@adrianforest4511]

If only Future was available in Australia! If anybody knows of an alternative that is available in Australia as of 2019, I'd love to know about it!

[@axtmann]

www.polish-up.com.au/products/pledge-floor-care-multi-surface-floor-finish-798ml.html Pretty sure that's what you need @@adrianforest4511

[@GuamBaybe97]

Amazing videos like always. Thank you for sharing these tips!!! How about using a rotary cutter? Might lessen the chances of tearing? Just a thought 😁 love your videos!!!!

[@DavesModelWorkshop]

Thanks Christina. A rotary cutter would solve tears, but it might curl the edge of the cut? Hmm, I'll have to try it and see.

[@anthonysheffield5717]

Dave, have you ever made curved sheets? I might have to do this in HO and 1/35th scales.

[@DavesModelWorkshop]

I haven’t, but it wouldn’t be too hard to curve the sheets as long as the curve is aligned with the corrugations. If the curve was at 90 degrees to the corrugations, that would be tricky, the foil would kink I suspect.

[@jefferymarshall6231]

Do the same with a piece of the styrene

[@tlclstuff]

My first thought was, have you tried shaping the tin foil on the corrugated plasticard (might be cheaper than buying this tool)? You could then make up to A4 sized corrugated sheets. And secondly, it looks a bit fragile... have you tried using thin (10 thou or less) plasticard and a hot air gun instead of tin foil?

[@tcj226]

Almost exactly what I was thinking too. You can also get heavy duty aluminum foil at the grocery store and it's surprisingly thick, takes shapes really well. Use that on a sheet of corrugated plastic and you probably save yourself quite a bit in the long run.

[@kurogiza]

Nice. How about using the foil from a whiskey bottle (like you have in another of your videos)?

[@DavesModelWorkshop]

I considered it, but I need to make a roof that is 40cm x 15cm - I would drink myself to an early grave to cover that kind of area!!! :D

[@bugler75]

Can you use a guillotiné for paper for cutting? It does look therapeutic though!!! Nice piece of kit that I might invest in for for the airfield diorama that I’ve started 😊

[@DavesModelWorkshop]

I think a guillotine would be perfect (I just don't have one). If you haven't seen Luke Towan's video, he also uses this tool to make a freestanding country shed - worth checking out for an airfield structure? Dave

[@bugler75]

Dave's Model Workshop I must take a look at that. Luke has some great ideas😊 Ta mate

[@captainjohn787]

Bought one of these for N scale, but it's pretty tedious to work with the single sheets it produces. A four-up, or at least a two-up tool would have been more practical. Nonetheless, the tool nicely fills a need for scale size corrugated material that is otherwise nearly impossible to find.

[@TippY_AshwooD]

Great Video. I too was wondering about using a pop can ( Coke ,7 Up, Pepsi etc). so that the sheets would be less fragile. Do you think the tool would cope with that extra strength ? is the rust technique the Rust Video ?

[@DavesModelWorkshop]

Hi Bob, hmmm, a soda can could work, but it might be a lot harder to get the initial corrugations in (I can just see myself slicing my fingers open...) I'm going to release a video on the rust next week, it's all paint, no rust solutions. Cheers, Dave

[@soupfork2105]

Have a look in your local supermarket for Bacofoil. It’s thicker and stronger than regular aluminum foil. Their turkey roasting foil would work well with this and has got to be much cheaper.

[@adrianforest4511]

Bacofoil is a UK-only thing, right? Maybe there's some heavy duty kitchen foil available here that might be usable.

[@donalddavis5996]

Would that work with soda can or a roasting pan could you try it and see how good it holds up

[@DavesModelWorkshop]

Hi Donald, it wouldn't work well with a soda can, I think the metal would be too rigid for the corrugations to work well. But it works perfectly with foil BBQ trays - I use these all the time! Cheers, Dave

[@colossalbigfoot256]

Cooking trays from dollar tree works great. You think this tool would work with that? I find I’m bending foil all the time. I built a jig using angle brass that works but wondering if this would hold up.

[@DavesModelWorkshop]

Colossal BigShot I’m busy looking for a more viable alternative that’s more durable, and I think cooking trays could be just the thing. Thanks for the suggestion.

[@stephenvaden4718]

Cool! Quick question. Do people in Australia say "the bee's knees" a lot, or is that just a quirk of your's. Either way I think it's fun!

[@DavesModelWorkshop]

I think it's a bit old fashioned, but not uncommon. I think I picked it up from my Mum, and she's 75 now.

[@jlpytlewski]

Once you do the 1st side, flip it over and lightly do the other side, takes the warp out of the piece...or not..lol.

[@DavesModelWorkshop]

True. Easily done, I agree.

[@cobbadog]

How did you do the rusty look, please?

[@DavesModelWorkshop]

If you search my channel for "rust" you should be able to find a video I did on this technique.

[@jlpytlewski]

Luke Towan has an HO scale tool, so they must make them for several scales.

[@DavesModelWorkshop]

Yeah, they do heaps of different scales, mostly geared to railroad builders, but I definitely saw 1:35 in the mix.

[@allanstott6999]

I saw several, but no 1/24? Is it classed as O scale or something?

[@keithaustin-brisbane6533]

Just wondering why you don't use/ demonstrate using the tool with the other part of the tool, that's what it is for

[@DavesModelWorkshop]

To be honest, five years on and I’m wondering the same thing! I use the second piece of the tool all the time now, not sure why I didn’t in this video…

[@davidquerry8869]

I don't know Dave, maybe you should have had a backer behind the panels. Anybody touches that, or tries to dust it, it will be all goofed up. Even with a backer, it is so fragile. Wonder if you poured a thin coat of epoxy on the back of it, so the corrugation holds its shape. Does look really good though.

[@ApriliaRSV4F]

I was thinking the same thing. What if you sprayed it the witered down PVA glue? Imagine trying to weather it.

[@DavesModelWorkshop]

Yeah, you definitley couldn't do something like hairspray chipping with this stuff. Pigments and very gentle drybrushing is about all it could take when it comes to weathering...

[@gamervince3720]

Just an FYI. The reason your foil is "tearing" doesn't really have anything to do with the sharpness of your blade. It's because there is no weight at the opposite end of the foil. Place your finger or something else on the other end, and it should eliminate the tearing. Also, in real life, very seldom do cutting shears (that cut through tin roofing) give a clean cut.

[@giglionero5961]

Hi, exist for 1/72 scale?

[@DavesModelWorkshop]

Yes. Google "Brunel Hobbies corrugated iron maker", there is definitely a 1/72 version on their website.

[@giglionero5961]

@@DavesModelWorkshop thank you :) one question: do ypu know if anyone sell something of similar for europe? I've seen this product, very good quality and good price, but i spend a lot of money for spediction and douane taxes :/

[@DavesModelWorkshop]

@@giglionero5961 sorry, no idea.

[@calvinehlert4756]

hmmm, alot of "tin" cans have that same pattern on them-hiding beneath the label!

[@DavesModelWorkshop]

True. But this tool comes in different scales, which would be perfect for say 1:48 or 1:72 dioramas (I can't even imagine working with this thin foil in 1:72 scale!)

[@calvinehlert4756]

@@DavesModelWorkshop I would not want to try 1/72 either! that's why I've been working with 1/25 & 1/16 in truck kits and 1/48 & 1/32 in aircraft. I'd like to see the army/marine stuff get away from 1/35 and more larger scales! oh,I found one tin can that has a continuous set of ribs -will have to see if it can be measured to see what scale it is close to!

[@bebble985]

First.. I hope if not I sound pretty stupid dont I?

[@bebble985]

Yes you do

[@brandonyuan6542]

Time to make a bob Semple 😂😂😂

[@DavesModelWorkshop]

Oh. My. God. YES!!! You just inspired me!!! (I loves a Bob Semple tank!)

[@tedjones8744]

What and you didn’t share the chocolate.

[@DavesModelWorkshop]

Heh heh!

[@user-nw1cb8ky8j]

take a piece of decking board worth $0.

[@kevinbrister8801]

I just did a google search for Bruno models, all it listed was some gay lookin dude posin for the camera! Whats the link to get this tool please?