How To Make Profile Dies For Any Bodyline - Home Made Metal Shaping Power Hammer/Pullmax

[@mightymikethebear]

These videos show basic machining and tool and die making processes that many of us can use at home. Thanks!

[@steveveness3829]

G'day from West Australia,😉 3rd gen Automotive Engineer with 43yrs trade life, that actually learned Coach building from some of the old masters in Sydney NSW my father grew up with, is tipping his hat to you buddy. ( old school sign of respect lost on todays world). Well done me thinketh🙂👍👍

[@Isadore123L]

The ability to tilt the table on the die filer is commonly used for making a draft angle in 'split dies', allowing a punched shape to fall out the bottom of a progressive die set. CNC Wire EDM machines displaced die filers the way the FastCut displaced torch and shears. You can get your form tools to sit proud of the tool holder faces by compressing metal shims in the bottom of the tool holder troughs. Toolmakers use thin, foil shims for setting gaps perfectly. Shims allow the interfaces of form tools 'bottomed' in holder troughs to achieve a perfect gap with tools 'centered' in the holders. The best 'centered' condition is to have the form tool shape doing the heaviest work centered in the tool holder troughs in alignment with the shaft hammering forces to keep forms, shims, and holders all in compression. 300-grade stainless for shims/foil works great because it work-hardens to higher yield strength than the 1008-low-carbon-steel, body panel as forming pressure hammers away. The overhang (cantilever) off to one side in the holders was a quick solution for the video, but that quick fix can lead to trouble maintaining constant tooling gap while forming sheet metal, especially on thicker stock or large upset shapes.

[@joell439]

Thanks Jim for your awesome input. It really helps. 👍👍😎👍👍

[@MakeItKustom]

Once again, taking us all to school! Thanks Jim I enjoy your lessons

[@IlhamTasrid]

Thankyou sir

[@mikecrout1214]

Sweet. Two things I would have done in addition to your work; I would have created a jig to hold future patterns that have corresponding holes to the tap screws and drilling dimples in the patterns to hold them in place.

[@christopheranderson8275]

Check out hard sculpting wax for the molds rather than Bondo. It’s formable when warmed but becomes quite hard once it reaches room temperature. I warm mine in an old crockpot. They sell 3 hardnesses. I’d get the hardest one. I use it to form master molds out of silicone and use them to make various fiberglass parts. You’re gonna love it for that purpose and possibly more uses for you considering the type of work you do.

[@lompatin]

Wow, this guy is really impressive! I would love to learn more about the tools you use in your shop. Would it be possible for you to create a video showcasing all of your powered and non-powered tools, and provide a brief explanation of what each one is used for? I think that would be incredibly informative and interesting to watch.

[@brentfellers9632]

Been a HD mech/ hotroder/ Aircraft maintenance engineer/farmer for 40yrs (now semi retired)in north east BC. you are a true inspiration. I have too many projects and not enough $$$$. I get too emotionally involved with my art to sell it duh...yard full of hot rods ,motorcycles,sleds 4×4s plus sxs's and quads. I chase away all people wanting to buy, and let the thieves steal what they want....😮 gotta change my business plan lol.😅

[@garywalters4286]

Use lead solder to measure the thickness,lay a strip down lengthwise and press the two dies together and measure with calipers.

[@MakeItKustom]

Great idea😆

[@johnnystewart9389]

i love it "metal shaping with garbage," thank you for taking us on the learning journey about power hammers. very enjoyable for a budding metal shaper.

[@christopherohara9421]

You are so talented you make me feel like such a hack

[@MakeItKustom]

😂🙏🙏

[@Manandmachine772]

Karl, you hit it out of the park showing what can be done with some time, ingenuity and just a little $$.

[@danielhughes9556]

Junkyard wars was an awesome show. It definitely needs to come back!!!!!

[@TCreatorO]

This channel is extremely underrated, very good quality content, I really appreciate all the work you put into these videos 😎👍🏼

[@juanrafaeltosado1812]

YES SIR, AGREE WITH, YOU RALPH'

[@michaelguinn5736]

Afternoon Karl, great job on your scrap built Pull Max!!! Seems to work fine!! The only improvements I can see would be to heat treat the dies, install bearings where you have metal to metal contact....

[@MakeItKustom]

Thanks Michael!

[@dylanbennett2673]

I grew up watching junkyard wars! That takes me back, really wish they would bring that back.

[@stephenmonaghan6030]

You really look as if you enjoy your work. The thing that surprised me most about this video was that you were surprised it worked out so well. Great job!

[@TK42138]

A great result. Couldn't help grinning seeing that test example matching the profile on the car 👏👏👏

[@franksgarage8551]

Well, that’s kinda awesome! I didnt think it would work that nice! Yet here it is, suprising us all. Thanks again for the inspiration Karl, and Elio!

[@MakeItKustom]

Thanks frank!!! Yea surprised me too 😆

[@murdoc6501]

Fantastic! Everything about this was awesome. Thank you. Go Japhands, keep moving forward! and enjoy your Australia expedition! Can't wait to see what you and Benntts Customs get into!

[@TriXsterStudio]

I'm doing the exact same thing right now ... making Pullmax dies on the Bridgeport fof our Trumpf TAS500 (Pullmax). great timing for this video ...Keep it up you're inspiring.

[@danamcintyre3565]

All it take is some thought and know how to do these types of bulds, then you just put your olan into action. Trile and error is how you lern ! Love the context of this channel you may not have the equipment to buld exactly what he has to do this but i truly believe it can be done !

[@ESCOTCH]

These vids are the best when you have a buddy in the shop talking it through like this... very enjoyable to watch. Interactive camera buddies are the best kind...

[@adamfaris9375]

I like watching the clock to figure out how many nights passed for the build. This is a great series and I enjoy the channel content. Thanks

[@DanHancock-e7o]

I have seen the shrink and stretch machine made from the air hammer but this is cool for a lot more thanks for showing it.

[@marciabaldwin2506]

Great video Karl in the UK junkyard wars was called scrapheap challenge a brilliant programme use to love watching it and scrappy races to. many of the old crews use too vehicles made from scrapyard all over the UK keep up the great work and brilliant content ❤

[@thatguy83ful]

That's really good for a few hours of work at the end of the day. Great video man

[@jeanlawson9133]

Yes I would love to see you host Junkyard Wars....You are an awesome 😎 individual never doubt it Brother.... I have a had a setback in my journey through this beautiful world...But I get to live through y'all..And the great content of your recordings.... thanks 😎 Scotty

[@tkirkwood3366]

I am so empress with your ingenuity and watch everything you post. Thanks

[@timr.3108]

Pretty awesome. And you made it look so simple. Might have to build a machine now.

[@MakeItKustom]

Please do ! You will have so much fun with it

[@timr.3108]

@@MakeItKustom I have evrything lined up, except a motor. Can't find one like yours.

[@gordonadams9038]

Thanks for your video. That’s a cool machine I have a machine shop and play around with cars also . I probably wouldn’t go out and buy a machine like that but spending the time to make one would be a nice project. I had a old sewing machine motor but gave it away . Now I wished I still had it . I love your projects I wished I lived closer to you. I’m older and have lost a lot of my friends. These videos keeps me interested and makes me want to keep doing something. Thank again from Vermont

[@theosgrandpa]

I made one of those from an old scroll saw to cut square, it works pretty good, using a file of different shapes, and size

[@richardsmith-qy6vl]

Another great video you really did a good job with a pile of junk now you can get all the parts and refine to be just like you want.

[@waynegilling6048]

you and your site are a God's send for those of us who can't afford to purchase every tool in the store when we need it. I have built most of my shop tools as I need them and they do the job required of them. thanks for the ideas and your knowledge.

[@williamday3727]

Thats crafty bud. Y'all do some awesome things. I like that seat you made up, make a nice seat for my welding station

[@williamgoodwin9667]

Well I never new a power file could be so satisfying,thanks heaps for all you do for the you tube community. My father has an old power hacksaw omg that thing is very satisfying also and will chop almost anything. Just need a little time.

[@williamgoodwin9667]

Oh and by the way your a bit a genius what a great job the machine did.

[@donaldhalls2189]

Very handy machine 😮 very well built, excellent machinist, thanks for sharing, all the best to yous and your loved ones

[@kennethcarver9687]

Just watched your video, all I can say is WOW, plans would be great for the backyard diyer, I can't wait to see what you do next, way to go from Nova Scotia 🏁

[@jasonshaw9240]

Absolutely awesome 👌 really like looking back at these posts you've done. Brilliant 👏

[@HappyHarryHardon]

I have a Pullmax that is a prized possession along with a Tin Man’s Garage Planishing hammer serial number 12. It fun making things in things you made. Good stuff.

[@juscozcustoms]

I have already taken up the challenge to build one. I went on marketplace before I had finished watching the last video and got the only sewing machine motor within 300km. I'll make a video about it and you will definitely be credited because this is awesome

[@NicksGarageUk]

I am doing a body swap in the uk with a Miata chassis and am attempting panel work for the first time,, I have done a bit now and honestly watching your videos has helped massively 👍🏻

[@jhitt79]

Junkyard Wars was an awesome show. I wouldn’t have guessed this guy was old enough to know about it.

[@BG-fm7zj]

This is fantastic. I have to say that it seems like this could be fit with English wheel/planishing hammer dies to give the hobby guy a single machine that allowed all 3 functions. Love the music, I do wish the filming was a little brighter at times but overall this channel is so fun to watch and SO MUCH to learn from each episode. Thank you!

[@ToreDL87]

Yeah you can make it work either way, or even in a big table vice, or in a hydraulic press. Lots of ways to do it :)

[@scottfrost2308]

Loving these power hammer vids! This has been the motivation i needed for building one myself, after watching your first vid, i pulled all my scrap and offcuts together and got to building something simular, its all 3x6 rhs and 4x4 shs, 1/2hp 240v singer motor, same linkage syle, and 3:1 belt reduction and 34mm stroke on the crank. With any luck I should have it running this weekend! Thanks for the motivation and great vids 👍

[@pureblood324]

I must admit watching this from concept to prove has been very inspiring

[@darenengelage2803]

Been watching your channel for years! This is going to be my next machine. Way cool! Keep up the great work!

[@t.l.hubbel5464]

Another excellent, educational success! I couldn't love your videos more, and I'm very glad I found your channel. Now, back to binge-ing your videos. THANK YOU!

[@PatHaskell]

Amazing! I fully expected it to put a curve in the metal sheet instead of staying straight.

[@shotsrodder]

You never cease to amaze me Karl 😎 let’s get back on the cab over 😂😂

[@rickmcendree6869]

Awesome work, just cool to watch.i think I needa machine like that

[@christopheranderson8275]

Hell yeah! Junkyard Wars was an awesome show. I do miss it!

[@fredbarnes3969]

great! I bought a die filer in a junk yard for $20.. I have a Kent White stile hammer From scrap. great stuff. fred

[@davidbutcher1105]

The next machine you should try to build is a wire EDM machine. That would give you the ability to make matching dies more easily.

[@nicklepage3842]

I have a wire edm. It's as reliable as a machine as Casey anthony is as a babysitter. Cutting pre-hardened steel is pretty cool though.

[@davidbutcher1105]

@Nick Lepage Goddamn! 💀💀💀 Well, it would still be a cool project.

[@TCreatorO]

Electronic Dance Music machine? I completely agree 😎👍🏼

[@MakeItKustom]

I’ll have to look into those machines a bit they look neat

[@davidbutcher1105]

​@@TCreatorO 😂😂😂

[@ddoherty5956]

Use a feeler gauge in both sides if the die when you set the top die perhaps? Absolutely awsome job mate 👍🇬🇧

[@adee-H1066]

Fantastic,I knew it would work.I really want to build one now,but I reckon my neighbours would go nuts if I started thrashing that around in the evenings 😂😂

[@nee3029]

It's been a while since I last visited this channel. The first thing I noticed was that you moved to a different workshop. Oh I must have been gone a long time lol. But the content is just as good if not better than before, I'll definitely be checking back more often. Keep it up 🤟🤙

[@SuperBossman9]

Man, tap magic smokes like crazy! I sometimes use it on my lathe but then I remember how much I hate all the smoke.

[@laurent6153]

Bonjour Karl, un bonjour de Paris en France, superbes vidéos on attend avec impatience la restauration des véhicules. Merci pour ton travail. Hello Karl, a hello from Paris in France, great videos we are looking forward to the restoration of the vehicles. thank you for your work

[@minnesotatomcat]

That’s incredible really for the very first go!

[@reneprovencher8395]

Man what a great video!!! You are a master with metal working. I heard DD speed shop loved your abilities!!! Yeah Carl, beautiful stuff. That came out GGGGGREAT!

[@koolkar55]

Can't believe you still don't have either a Pedestal or Benchtop Drill Press. I know you have the Milling Machine but they are so handy.. Billy J...... Queensland, Australia.

[@MakeItKustom]

Haha I have two actually

[@koolkar55]

@@MakeItKustom You love your hand drill though? Go figure!! 🤔

[@colinwhite2401]

Yup good job Karl. Surprised me how good it works. I think you could sale kits for it easy.

[@markpollard500]

Very impressive for a home built machine! Your an inspiration to me an I'm sure many others!. Love your channel.

[@kyleforeman4543]

Nice dies for first time , luvs those end mills,,an never a file mach before,, sweet..tks for sharing

[@davidlouis2354]

Man, you have some serious inventor genes. I sometimes think that you have more fun building machines than you have with cars, but ultimately they are the same. I first thought that you were going to show a vintage movie about electric cars. Keep up the great work.

[@MakeItKustom]

I actually do lol machines are soo fun

[@jimw6991]

​@@MakeItKustom I worked as an automotive engineer my entire career but on the design side. The guys on the manufacturing side seemed more creative, the tools/machines they came up with we genius. I am not surprised you are enjoying turning scrap machines, steel into something useful ... great video and keep up the good work.

[@glennmiller9031]

I love that tool. So cool. Works amazingly fast.

[@SchysCraftCo.]

Hell yeah I am down with that. Juck yard wars. Awesome video as always. Can't wait to see more videos soon my friend. Can't wait to see ur trip up to benetts customs video. Keep up the great craftsmanship and hard work my friend. Forge On. Fab On. Weld On. Keep forge lit. Keep Making. God Bless.

[@crazywickedcustoms7272]

Just watch this video again, I am more impressed with it. I building one for sure now, thank you

[@greglammers9905]

Nice job. Years ago I bought an old nibbler that will cut 3/8ths thick steel. It is from the 1930’s. It’s huge and weighs about 2500 lbs. my plan is to make a planishing hammer out of it. Love the videos

[@steelcityperformancesaws]

i use to love that show, junk yard wars was great. that and monster garage were two shows that gave me a lot of inspiration

[@gloorfpv1801]

Probably the most impressive fabrication show I’ve come across,,, also junkyard wars was definitely a favorite,,, scrap heap challenge was also fun 🤩

[@adambergendorff2702]

I have got to stop watching this channel, my garage/shop is already full of tools I couldn't live without!!

[@LPOneThree]

I saw an episode of Kin-dig-it along time ago where they made dies for fabrication. I always wondered how they did it. I have been waiting for a video like this for a long time. Another great job, thanks.

[@jeffpitzer8521]

Wow Karl! I have a Pullmax and a die filer...but until your (this) video didn't realize that they went together as a pair!... unfortunately my die filer doesn't have the over the top arm, just the bottom file attachment which requires the reverse die filer files that have the tang on the down stroke... but you have my brain spinnin'...kool how two different men from different countries that have never met influence each other...or one... I know that I could show you some tricks if you you knew who I I was..awesome video! ...😊

[@MakeItKustom]

Haha!! Stoked you like the video man!

[@keithroute8906]

Very cool, would you be tempted to laser heat treat and harden those profile piece mating edges to have them last virtually forever? We used to laser the teeth to make them hard on the wheels for monster vehicles used in mining to make them last way longer. You are amazing in the things you do. That really worked next to perfect, way to go.

[@richardcartier3578]

Impressive - now you got me looking for a sewing machine motor - probably never need a Shaping Hammer - but it would make a great addition to the tool collection, and you make look so easy to build!

[@NjalLaing]

Very cool result, much impressed 👏 thankyou for the journey on this build

[@lesgaal4017]

Hey mate a tip for glass finish on steel is to us Kerosene and fine wet&dry that's what we used for years to polish our injection molding dies. Australia

[@hisab-n8c]

Great job👍👍, looking👀 forward to your plans

[@gardos-garage]

G'day Karl, love this episode, so informative. One thing I did think as soon as you marked your cut, why not use the straight side of the bar and only cut out the curve. This would also strengthen the die.

[@timbercretesteel9855]

Clever man! Great to see skillzz!

[@mikeyazel8725]

I loved seeing you use the filing machine as I have one in my shop, next time try angling your working area of the die to spread the forces equally. Draw a line from one edge of the die to the other through the form section and then make the mounting surface parallel to that line this will reduce the side load on the tools and machine. Keep up the good work. 😅

[@toddabraham7724]

I bought a filer years ago and haven't used it much. I like that yours can accept regular files. Mine requires a special file and they are expensive...... I have a Trumpf 901 reciprocating hammer.

[@johhno9331]

A couple of pieces of the metal that you are going to use as a thickness guide would speed up your process. Cheers john from Australia

[@Group-Five-Industries]

I love this stuff!!

[@brandonparr6345]

Thanks to you picking up a 3/4 HP clutch motor. Can't wait to build!! Anything you would of done differently to improve design?

[@ponga782]

That is a badass power hammer/planisher!

[@moormarx9248]

maybe my favorite 3 videos from you. The list of tools i have to build is getting longer and longer, you are building machines way faster than I can keep up with. Thanks for your videos

[@gregorycatren3442]

Alright 👍...let's work on the Zephyr.. I can't wait to see what you your Zephyr is going to turn out like... Mike Bellows did a fantastic job with the one he did...I know Karl you are more than capable of the same quality of craftsmanship....I know summer is just around the corner,and you will hopefully be going to take your bad ass rat rod truck out and hopefully let us go along.. But your Zephyr,your dream car is sitting there saying please work on me ,I need more of your attention PLEASE....

[@nelashharinarain3394]

Excellent machine. Thanks for sharing. What a great finish.

[@scottsprague9974]

That is awesome Great imagination. Tools from scrap.

[@michaelanderson3771]

Karl- Awesome results. Could you also do that around a curver profile to match the arch of the line- as the rear droops off the back of the car? Absolutely fantastic home built tool. I can see you using that much more on the Zephyr

[@domenicozagari2443]

Torpedo 1 loose :) You can put a treas on the bottom part to screw the height.

[@TBS_Machine]

Cool tip I have a die filer , shopping for a pullmax

[@simonilett998]

Hey Karl, nice job as always mate. Was nice to meet you briefly down at Jordans today. Didn't get a chance to say, love your work, love you channel, I've been a subscriber since I saw your hammer + dolly, shrinking disc videos you did on the 40's Willys hood a year or two ago. Enjoy your visit Down Under, and safe travels bud👍🇦🇺

[@matthewmoilanen787]

Nice to hear commentary from Elio! Keep after Karl big E, a little sass will keep him humble.

[@MTLHD-y8c]

Appreciate the experimentation and enthusism and your willingness to try new things. Some observations: The thumbnail dies being used as shown in the Sosa power hammer really make a mess of the metal! The arc of that tools swing cannot possibly bring these thumbnail dies together into proper contact or alignment for them to acccurately shrink and leave a clean metal surface.. These type of dies are used in Yoder power hammers and later adapted to Pullmax machines..Both have vertical strokes and adjustable tolerances that allow a controlled shrink and setting down of the fluted metal. A suggestion: Try adaptiing the thumbnail dies to fit your home made pullmax style reciprocating machine- like you do with the profile dies.

[@ingefrainromero5109]

Excelent My friend... Thanks for share all your know how.... God bless you

[@danielbuckner2167]

Karl, what up!? Hey, this is so cool I had to get thicker socks. The only mod I would make is having an adjustable stroke length (which could be done by having an extra hole on the linkage up top) so it can be used for some blacksmithing trip hammer uses like the monotony of texturing spindles for gates or what not. Bark textures require lots of time by hand and are not a super deep texture but having a trip hammer for that would be sweet!

[@mikeobrien6954]

Great machine and proof of concep. Waiting for someone to build one with bearings and maybe an adjustable stroke. How about a set of dies for shearing.Keep up the geat content