Make Aluminium Car Parts in Just 30 Minutes with NO Experience!

How to Create Hammer Formed Aluminium Parts for Your Car | Tutorial with Chris Hollier
In this hands-on tutorial, Chris Hollier, an experienced car builder with over 100 custom builds to his name, shows you how to create aluminium parts for your car using simple tools you probably already have in your garage. As a former Kit Car manufacturer and Editor of Kit Car magazine, Chris brings a wealth of knowledge and expertise to this detailed demonstration.
Whether you're working on a custom build, restoration, or just want to learn the art of metal shaping, this tutorial is perfect for anyone looking to expand their skills. Chris will walk you through each step of hammer forming aluminium to create precise, professional-grade parts that fit your car perfectly. No fancy equipment needed-just basic tools, patience, and a bit of practice!
Subscribe to our channel for more expert tips and car-building tutorials.

[@paulnewton943]

Yep ! More please as well as grade and wedding ally. Thanks

[@paulgervasesmith152]

Excellent! More How To videos would be good.

[@7Spot556]

@@paulgervasesmith152 Hi! We’re glad you like it! If you’d like to something specific, let us know.

[@paulgervasesmith152]

@@7Spot556 I am new to the kit car world, and currently surrounded by a semi-dimantelled MK5! Tips and tricks on refurbishing parts would be good.

[@chaycock65]

Very interesting

[@MiniLuv-1984]

Metal crafting videos are great, more please. That blurring video effect has to go though - it obfuscates finer details.

[@Al-os2cg]

More on the mods at this level is good👍, I personally have done stuff like this with minimum resources.

[@TestGuyTony-st2ez]

Great Job H

[@7Spot556]

@@TestGuyTony-st2ez thank you! If you have any suggestions, please let us know.

[@OzGecko]

Good demo - two issues for me: - I would have worked the whole length of the flange over in stages which would have made that centre portion easier - why the annoying "solarize" video effect on the sped up parts?

[@mckutzy]

Very interesting.. always like seeing the hand forming of the aluminum... I see you did this with no annealing of the metal??? What type of aluminum is this??? 1100 or harder stuff like 6063??

[@Tig_Weldor]

I’m a motorsport/aerospace fabricator/welder and do a lot of aluminium forming. I’d say it’s either a 1 series like 1050 or 1200, 3003 or maybe but unlikely, a 5 series like 5251. It definitely won’t be 6 series as it would certainly crack without annealing

[@mckutzy]

​@@Tig_Weldor I was going to say, 1 for sure, not a 5 series.. see slight movements and looking at it wrong.. it breaks..

[@Tig_Weldor]

@@mckutzy this shape is possible with 1.5mm 5251. But I’d anneal it first. Probably even anneal it a second time after the first excess material has been trimmed, for a final bit of forming.

[@jimintaos]

Sometimes I wonder if the algorithm is telepathic. I am working on an aluminum skin trailer and need to make some "eyebrow" rain deflectors over the windows and door. I made one and was fairly disappointed with the results. I am going to give it another go using this technique. Thanks

[@anthonywilson4873]

This is similar to how aircraft parts are made by hand, they use a special alloy that is really soft, once the shape is formed they harden it. As you imagine it is carefully checked by an independent company for it forming and hardness.

[@eotikurac]

isn't aluminium dangerous to inhale?

[@mckutzy]

In this state its pretty inert... No more harmful than any other metal you would typically encounter.