HOW-TO Make CURVED FLANGES on SHEET METAL With HAND TOOLS Installing JAGUAR Gas Cap PLYMOUTH Fender

[@ddoherty5956]

A lot of people would scrap the video when the holes started cracking, but thats half of the educational value of watching you work. Thanks for sharing your Skills Karl 👍🇬🇧

[@blue32nu]

I really appreciate the editing of the sound. Like the grinding and pounding turned down, it makes for an enjoyable viewing experience ❤

[@paulouberprofissionals9918]

Que trampo top❤Qual o nome dessa tampa de tanque?

[@MakeItKustom]

Thanks for noticing! Cheers

[@peterwarren8521]

Brilliant as usual. 😅

[@Frankensteinfabrications]

Hey, wouldn't it have been better to cut a piece out of another piece of sheet metal 1/2 to 3/4 inches thick, then weld it in and grind it smooth ?? Anywhere I love your content

[@harrywalker968]

seeing thart@@MakeItKustom seeing that it has to be welded, , id cut the flange in about 6 places, makes for easier bending, & wont split. & yes, id grill holes first. not as many.

[@hickeyskustomresto]

Made mine out of a piece of 3/4 round stock, goes around the bend like no ones business. Showing these old tricks is a big help to many, well done Carl

[@That70sChannel]

That's a really good idea. I was thinking of a slimmer tool so it wouldn't bite into the corners is hard, but a round tool would avoid that entirely

[@Turbo2Pete]

I would say to use 3/16 bar stock, so it took a smaller bite, also, we used to use a tool that was a round rod for a handle, with two rollers bolted on one side. You slipped it on the edge and just roll it back and forth to flange the edge. What I had was 1/4 inch flanges, but a thicker wheel would give a wider flange

[@mrwebber35]

I'm #42 like... This video is showing us what not to do which I like. No point in criticizing as after a long day of trying to get somewhere kind of narrows your thinking.

[@jaredourada]

Came to say the same thing. Easier on the hands too. Also a bit longer for leverage.

[@probablyatroll8571]

Karl is a born teacher. This dude’s knowledge, skill and patience is fantastic. Karl, If you’re ever in the market for a middle aged inexperienced intern, sign me up!!

[@JaySea1069]

Diligence and patience and sense enough to back off and think it thru, nice work.

[@curtbelshe]

You are a premium educator. I especially like that you make mistakes (drilling holes) but can show us how to correct and move on. Always inspiring.

[@PaulyD0859]

My dad built tools for a special purpose, like you just did sometimes for just a single job never to be used again. I learned a lot from him and I'm still learning from guys like you. Thanks Karl!

[@joell439]

Very interesting. Certainly reinforces how Fitzee would approach this modification. 👍👍😎👍👍

[@tfs1150]

Thanks for the video Karl! My dad was a metal man from way back (1950`s) and I learned a lot from him. He used to watch me repair dents and always required metal finishing whenever there was access to the backside of the panel. He taught me to always use heat whenever I needed to re-establish a flange. I think that more heat earlier in the process might have avoided the work hardening that caused the cracking. I would also say, an 0 or a number 1 tip on your torch would have allowed for better heat control. But in the end, you made it work and look great, so Cheers to you for a super fly modification.

[@rickfazzini22]

The fact you try something new on camera and then post it with no editing (aside from sound and some FF ) is awesome. I know that feeling like the plans not working out and you then adapt and tweak and just don’t quit and it always seems to work out. Great job on the video and sound management !

[@ianquarterman9760]

the drain is for rainwater, as the cap sits flat ( horizontal ) on the jag, and the well would fill with water. great vid as always

[@mrwebber35]

I'm #15 like... He was doing this for his friend after all.

[@larryross1819]

Wow, talent, brains and patience. Metal is like clay, he shows that to be true. Great video, keep up the fantastic work.

[@notebender5073]

Takes a lot of guts to do something like this on camera even with the skill this fellow has. That customer must've really wanted that gas cap. Anyway, good job and thanks for keeping it real by showing the trial and error steps. I respect that. Good work.

[@twm4259]

It takes a lot of courage and self-confidence to dive into a project using new techniques on materials where you can’t go buy a replacement if you make a mistake. Kind of like a surgeon that is deep into an operation that can’t just go home when things aren’t going well and start over tomorrow. You soldier through and achieve a professional result. It is a joy to watch.

[@mattb.5103]

I enjoyed the working out how your going to make it happen and the corrections made along the way. Makes me want to get out and try that myself

[@ronwalsh]

I now know what a tool I found in my box is for. It was a round stock piece with a few cuts like yours, all at different angles. Glad I didn't get rid of it. Great work as always.

[@BarryGrumbine]

A couple months ago one of your videos inspired me to bang on some metal. To make a parts washing basin, I cut about 6" off the bottom of a 5 gal steel can and made the exact same flange tool to turn over the cut edge then hammer and dolly it flat. Works great. Thanks for the inspiration. You rock!

[@so_what_else_is_new]

I just love people who can make stuff with their proper hands!!!!❤

[@TheDistur]

There's some learning with new tools but you always find a way. I appreciate that.

[@leemorgan9203]

I enjoy that your honest with us, showing the process, not "mistakes" but learning curve. Thanks so much !!

[@peterrivney552]

Sometimes thinking ahead saves problems that arise afterwards good thinking 🤔😏 I remember working at a body shop where there was a body man working on an old four door hardtop trying to aline the side doors having issues with the door windows not fitting with the roof seal very well I noticed then the doors were off the car that the center half post was angled in at the top from the doors closing all the time slowly bending the metal inward I let him play with it for a few hours before I mentioned it to him to check the center half post for the front door latch and rear door hinges since it's not supported at the top roof area it will slowly bend inward with doors opening and closing or slamming shut and twisting the Angle of the door frame so the window hit the window frame before the door fully closed ...

[@mshort7087]

You’re a brave man. I’d have had to practice on a dozen junk fenders before I attempted it on the target fender. Thanks for taking us along

[@nv1493]

Once you get into your mind that you can often make what you need, it really opens up possibilities. I've made stuff that I've only used once but still well worth the time.

[@denniskalivoda]

Enjoy watching you work the metal as you sure know what your doing. As I was a welder myself, now retired.Nice job young man.

[@brucematthews6417]

I love these videos that show off a simple tool and technique that us guys with no room for fancy tools can use. Another first class low tech lesson video. THANKS !

[@bobbybrice6307]

I love that you always show the good and bad of doing metal work. Thank you Karl.

[@ralfwanner4201]

Thx for your videos, learned a lot through them. Stay healthy and balanced. Regards from Germany to you and all bloody Aussies Ralf

[@sufferedenuf]

Great job! You showed that even the experienced can learn.

[@jessemarin5044]

Great custom work, thanks for showing how you do it,1 step at a time good,bad or indifferent, it comes out with work.

[@russthebiker]

I love that amazing planishing hammer, it looks almost neolithic like the horns of some ancient mammal I would love to buy one,but i know i do not have the skill to use it,and would merely spend my workshop time polishing it and oiling it !!! I love watching you shaping and forming and teasing the metal to shape Its like being a chil again and watching my father create things

[@wow_cars]

I used this exact gas filler door on my Dad's 32. I wish this video was out back when I did it! Great tips, thanks!

[@alannelson6990]

Hey Karl, great educational video and it couldn’t have come at a better time. I’ve just started the metal work on my first project, a 72 Dodge Demon. I plan on using the fuel door from a 69 Charger. I now know how I’m going to do it. I use you’re videos as an educational resource and I’m quite pleased with the results I’m achieving. Thanks!

[@johnkranyics281]

Did the Challengers have a similar fuel cap?

[@MakeItKustom]

That’s great Alan! Thanks very much. I am glad to hear this was well timed for your demon Project!

[@alannelson6990]

@@johnkranyics281 Not sure what the Challengers had.

[@apexmetalrestoration2805]

Karl, you’re like the Bob Ross of metal working.

[@chauvinemmons]

Whoa there partner where are you trying to go with that what you trying to say

[@Spiritof_76]

@@chauvinemmons Why the surprise? Bob Ross was a master of his craft and both relaxing and enjoyable to watch.

[@kenkolla]

It takes time as you said. I once asked my grandad how they did the work back in the day without all the tools we have today. He was born in 1908. His answer was " We had the best tool there is... time".

[@iancook7315]

I love how honest you are .. I learn so much from your channel.

[@MakeItKustom]

🙏🙏🙏

[@paulhedman7387]

And it all comes together, I knew it would. It is fantastic the way we get to see your thought process as you work your way through the problems.

[@Bob_Adkins]

Yes, Karl and the viewers all knew how this was going to turn out, the adventure was how he was going to get there.

[@joeabad5908]

Wow, 4 hours for such a beautiful metal work.. Impressive..!!

[@danlemke6407]

Wish you were our shop teacher in metals class, back in the early70s. You have the gift.

[@JohnMcClain-p9t]

I know very little about the sheet metal, but I do know that it work hardens much faster than a solid thick piece. Trying to work a piece to shape on an anvil after it's lost it's heat always results in cracks. I suspect the sheet metal work hardens much faster than a thicker lump. That came out very well, even after the edges split. Always a pleasure to watch and learn. Thanks!

[@MakeItKustom]

🙏🙏🙏

[@theayatollahofrockandrollah]

you are a fine upstanding young Gentleman making it very easy to learn from you because of your friendly, mild mannered aura. May life bless and reward you.

[@ralfpescheck4343]

Even though it didn't go quite as well as you thought, you once again did a masterful job. You are a true artist. I am very impressed.

[@franklindner8259]

U pulled the rabbit out again. Love your segments on home made tools.

[@vernheidt1889]

Great video, inspired to do this on my 48 Mercury coupe. The drain should be relocated to the lowest area of the recess to allow draining any rain water or fuel overflow.

[@dukesgarage]

Thanks for sharing the mistake parts, it helps us who aren’t metal gods to better understand what happens when you think you got it figured out

[@sllimj1]

thanks, always nice to have helping hands who understand what your doing and understand what is needed next

[@rmckayne]

Fantástico! You Are , ( My Personal Opinion) The best in KZbin.

[@frankerhardkobow5931]

YOU are the Bob Ross of metal shaving

[@TradIrishHarper]

Air grinder? Nice. I need one of those. I have a gagillion spot welds on a 1950s Willys floor pan and that will make my like much easier. Excellent video. I can put that flange tool to use immediately on my project

[@brianjones6500]

When you are a sheet metal fabricator and own a welder every problem looks bendable and weldable. 1. that gas cap looks cool 2. why not save time and make it look good by bending the receiver to match the underside of the gas cap area. add nutplates then matchdrill the screw holes and proseal it in place so it won't leak. The gas cap "look" would then be surrounded by say 6 or 8 fasteners and it would have a cool "aircraft/vehicle" one off kind of look. I also like pop rivets and anything that shouldn't look like it belongs on what ordinarily should be expected. I think your show is amazing and I look forward to more insights on your perspective of how the world can be made better!

[@Chevypowered5766]

Great video Karl and another great tip for making the tool. The learning experience is amazing and for you trying the process for the first time and then telling everyone what you felt was a mistake you made, and don’t do it the way you did it so we don’t make the same mistake. That shows a mark of a good teacher and you caring about the ppl who watch your videos

[@DegenerateFabricators]

When it comes to art you must move slowly and gradually chip away until you find the sculpture underneath. Thank you for your wisdom

[@robertjones1709]

Nice work just the same, you brought us to School as well as yourself, "Every Day is a learning Day"-Gene Winfield Thanks! Karl ! This one was a great Video as always 👍

[@pbf64]

pretty cool alternative to stretching

[@rockharvey5787]

It’s cool watching you work through the problem-solving aspect of this project. Thanks for keeping it real and not editing all that out.

[@kiwibrett]

I built an adjustable depth one from a 1/2" bolt 6" long. Made a deep cut across the threaded end slightly off centre. This gave me a wide and narrow anvil for working different circumferences by turning the bolt 180º. Next I slipped on some 1/2" ID rubber hose to protect my hand, then wound on a nylock nut. This can be repositioned to make different depths of slot. Use a round cap screw [allen head] to be even kinder to your hand - you will likely make 1000s of tiny bends with it over the years. Cheers from NZ.

[@blazenlights]

Make it look simple, the evidence of a master. Impressive work!

[@leonhart2452]

Annealing works well, remember how well Brent's car was annealed and how easy it worked back into shape.

[@creepycrawler43]

Thank you for sharing the struggles man it’s so much more relatable

[@MIKEH.777]

That gas cap came out fantastic halfway through i seen the split and I thought you was going to have to do more work than you did. But you nailed it , keep up the great work and God Bless you and your family. 😊👍👍💯👌🙏🏼🙏🏼

[@keithroute8906]

I did something similar around ten years ago on a Plymouth. Someone side swiped the rear quarter and the gas cap got caught on something and it mangled the fill area. I cut out the filler neck area out of an old Chevy truck in the junk yard. The radius on the car was a little tighter than the truck so I tightened the radius then cut and welded it in. I did the big huge weld around the patch and new filler that you avoided doing it that way. I had two hours total in the job and it came out real nice. I could get to both sides of the weld with the trunk open with hammer and dolly. Not sure if I would even want to try what you did that would take me forever, but wow, great job as usual, you are impressive.

[@cherifowler137]

You are very brave and honest to show all the video showing the issues you had along the way! Fantastic video as far as production and how educational it is! Thanks!!

[@stevesloan6775]

Such a great video… I love the flow of the improvisation. That’s what makes it great!

[@westers1514]

Love you sharing the learning process and explaining what you'd do differently.

[@crouchingwombathiddenquoll5641]

Excellent camera work and editing. Thank you for the video

[@Macbetula-yl8wq]

One thing about metal, there's so much to learn. Great video's.👍

[@TgWags69]

Not taking anything away from your job, very interesting technique. I can't help but think how Fitzee probably would have done it. Take a 3" wide strip of sheet metal and bend it into your oval that fits your flange. Cut the oval into your fender and tack weld it all in. Then cut it and sand it to fit the curve of the fender. No worries about creating a flat spot by bending in the flange. I think he would have had it done in 20 minutes.

[@seanfitzgerald4052]

Nothing happens in 20 minutes.

[@MakeItKustom]

Yeah, absolutely I think it would’ve been much quicker to do it that way

[@rmTheWalrus]

⁠@@seanfitzgerald4052yeah, +100… nothing of any complexity happens in 20 minutes. I know the OP is probably exaggerating a bit to make a point, but I’m going to guess that some of the complexity here wasn’t anticipated until he really got into it, which is a thing, no matter how experienced you are. Been there….

[@TgWags69]

@@rmTheWalrus 😉👍

[@owenlambert6201]

Great to see from start to finish. Even with mistakes. Keep up the learning. Cheers O.

[@phillipsprangiii3112]

You set a high bar; we are all the better for it...by far. This video puts me that much closer to cutting the hip-ring hole in the roof of my 1942 CCKW cab resto-mod project truck...that has a chance to end up looking like the one they came with from the factory. You are a master, indeed, especially in light of your transparency regarding the evolution of a first time project, learning-challenges included. (lotsa syllables for "mistakes"...that are much more learning-curve moments than ****-ups, eh !? I'm a builder: I speak that language fluently. Got the scars to prove it.) Many thanks!

[@MakeItKustom]

Ha ha you got that right to fill up! Good luck with your project. Thanks very much for your support. Cheers!

[@bennymcmunn9683]

I always learn from you Kevin. One thing I like the most is you admit when you make a mistake and tell your audience what happened and you give the don't do what I did but give the audience sound advice on what to do. This says a lot about your character to help people learn. You are awesome 👌

[@MakeItKustom]

Thanks Benny I appreciate you! 👊👊👊

[@timr.3108]

Great video Karl. That process will work well for frenching in any opening.

[@MakeItKustom]

I would like to do some French to headlights on the Mercury! Good call

[@AgentWest]

Neat little tool. I made a very similar (just significantly smaller) one to open up those older mechanical gauges. Had a few that worked well, but needles were too fainted to see easily. It's sort of the opposite task with those since you have to de-flage their shiny "beauty rings" to get inside, but the idea worked well. If you do need to open one up, wrap the beauty ring with few layers of masking tape (so you won't scratch or stretch the outside), then un-flange the beauty ring on the back side and remove it together with the glass. From there you can touch up the needle, or remove needle and face all together for servicing of the gauge mechanism. In some cases you'll need to take couple nuts off the back of the gauge and the entire assembly can be removed from the housing. To re-assemble, put everything together and gently fold the beauty ring flange back down/in. Work on a piece of leather (piece of old boot even) to keep from scratching up the front of that beauty ring.

[@RealityCheckThat]

It's crazy how much knowledge you have and you're a great teacher. Love your vids and workmanship.

[@David-lg4md]

Nice work, Karl, you are very patient!

[@denisfarrissey6970]

Nice to see a expert admit when the process is wrong and how to put it right, my brother was a sheet metal worker and made rollrice wings for old rollers amongst other stuff but yes it is nice to see a expert working metal thank you.😊

[@johnnightingale7485]

I wish I could drive my ‘82 Vanagon Westy up there and build a custom headliner pan

[@SimplyStatedArchitecture]

I appreciate the attitude of your videos - that "we're" learning. So many videos show you the finished results - or the "final" process to get there. You show the thought process as you go along. Ok, here is where we're starting - well, that didn't quite go as planned - let's step back and think - ok, we're going to attack it this way. Not only does it give the viewer a larger arsenal to work with, but it emphasizes that it's a process and not to get discouraged when it doesn't work right away or with the first method one comes up with.

[@MakeItKustom]

Right on! I appreciate your support. I truly am learning every time I do any of these processes, and the fact that it also helps other people understand, watching me, is the best complement to the channel. Thank you!

[@yona1948]

Learned this from Ron Covell in the early 2000's ... great instructional ...

[@peterouellette3874]

Try using a solid 1in 12ins long round bar as your hammer and shape your dolly to what you need, I use half in or 3/4 flat bar, nice to make itonger, best hammer Fairmount 162 and shape the heads as needed

[@pirateradio1926]

Bro, I really love watching you explain things. You are substantially skilled, but the fact that you show your struggles as you experiment with new things makes this feel so approachable.

[@mikewasniewski4048]

I made those back in the day.I used round bar . Good job!

[@MikePatten-k6l]

as always, it was a fantastic learning experience! Thank you Karl.

[@joeabad5908]

Im not a metal sheet guy.. But I am enjoying this video.. Such attention to detail and very good explanation from start to finish.. Thank you for uploading..

[@johnlreim]

I think this is the most useful youtube channel there is. Great work and much learning, thanks.

[@terrywillis5784]

Great finished product. You are a Master with a hammer. That fender looks great again !!!

[@glenmiller3783]

Great video Karl, when you don't have the tools it takes a lot of imagineering to get the results your looking for.

[@thebeardedone1225]

After doing a couple of these by hand, I modified a small pair of needle nose channel locks by getting the ends red hot and bending them in towards each other. This allows you to tweek that edge by squeezing it together instead of hammering so much. Plus it helps hold the flange for the tack weld. Your final product looks great, which is what it's all about anyway.

[@thebeardedone1225]

When heating up the plyers its necessary to have a piece of rod to clamp the plyers to while heating it up, to get the necessary gap. Pinchers are sometimes better than a hammer. 😊

[@Allen.Hickers_]

You are truly a sheet metal doctor

[@stevechovan1696]

I did a cap similar to that on my MGB. I cut the hole made that flange and bottom piece to mount the cap to and welded it in around the oval. Came out great.

[@TheTrooper777]

Awesome job,Carl you are great

[@gregl1824]

You really are a true craftsman and a great teacher. You make it look so easy. Hope to one day attend a class that you put on.

[@333111444333111444]

A guy showed me this trick a number of years ago. Since that day I've showed as many people this trick as will listen

[@floydbecnel3434]

Hey Karl , thanks for another great class. I have short crescent adjustable wrench I use for flanging . It is about 5/16 inch wide and works great in tight spots.I also have a homemade wrench like yours, but mine is bent into right angle .works great. Please keep these videos coming!

[@peterspicer3740]

Hey Karl. Just a thought I've had over a couple of your videos. When you're planishing by hand, the fast motion takes away the sound of the hammering. It would be good to occasionally hear your hammering to get the gist of when you are on or off dolly. I think that is part of getting the feel of what you are doing.

[@MakeItKustom]

Thanks for the feedback I appreciate it!

[@patrickphelan5863]

It's only a mistake if you or somebody else doesn't learn from it. Great work.

[@mikearmstrong7866]

I absolutely love this kind of stuff. Thank you for the opportunity to learn!

[@bobbiehenry4693]

The sign of a craftsmen Is being able to correct mistakes! Well done.

[@shutupstoopid4518]

I do this with stainless sheet, use a 1" square bar about 12" long and cut a slot in the end of the bar about a1/4" in put the thin side to flange and the fat side to the panel and pull from underneath more leverage more control

[@billmcgarry3300]

Great Work and a Big Thanks for sharing your experience!

[@vesap8511]

That's good job as usually You works . That was nice to look and learn how simple tools can get perfect end.

[@bottrelbetty]

Loved the heating part Karl, you'll become a blacksmith one day bud! Narrower piece of steel with rounded corners might have worked better on the tight radius? Hammer it out on your anvil.....