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🙂👍👍

[@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.

[@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

[@christopherohara9421]

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

[@MakeItKustom]

😂🙏🙏

[@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'

[@TK42138]

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

[@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!

[@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.

[@Manandmachine772]

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

[@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.

[@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.

[@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 😆

[@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.

[@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!

[@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.

[@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!

[@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.😅

[@dylanbennett2673]

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

[@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😆

[@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.

[@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...

[@tkirkwood3366]

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

[@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

[@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

[@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 😂😂😂

[@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 !

[@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.

[@jhitt79]

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

[@donaldhalls2189]

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

[@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 :)

[@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.

[@pureblood324]

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

[@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

[@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

[@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 👍

[@christopheranderson8275]

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

[@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

[@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.

[@thatguy83ful]

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

[@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 👍🏻

[@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 🏁

[@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.

[@rickmcendree6869]

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

[@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

[@darenengelage2803]

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

[@minnesotatomcat]

That’s incredible really for the very first go!

[@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

[@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 ❤

[@PatHaskell]

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

[@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.

[@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 😂😂

[@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!

[@shotsrodder]

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

[@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!! 🤔

[@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.

[@jasonshaw9240]

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

[@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

[@crazywickedcustoms7272]

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

[@colinwhite2401]

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

[@gloorfpv1801]

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

[@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

[@ddoherty5956]

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

[@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

[@kyleforeman4543]

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

[@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.

[@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 🤟🤙

[@glennmiller9031]

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

[@markpollard500]

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

[@307Garage]

that worked better then I thought it was going to.

[@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!

[@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!

[@ponga782]

That is a badass power hammer/planisher!

[@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!

[@ralfgottfridhansson3127]

Great job👍👍, looking👀 forward to your plans

[@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.

[@Group-Five-Industries]

I love this stuff!!

[@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.

[@matthewmoilanen787]

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

[@lancemclean9273]

That work’s pretty damn good for scrap

[@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. 😅

[@NjalLaing]

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

[@trailfreekgarage]

Hell yea I wish they would bring back Junk Yard Wars!

[@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....

[@adambergendorff2702]

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

[@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

[@scottsprague9974]

That is awesome Great imagination. Tools from scrap.

[@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

[@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

[@OGTtom]

Too cool Karl , making things instead of buying , good job

[@nelashharinarain3394]

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

[@n1352-m1i]

what a killer topic ! I've been wondering about that for a while (yes, I should stop procrastinating, I know, I know...) thank's!

[@1936fordcrazy]

I want to build one of these so bad, I literally just brought home my first mill and lathe and am currently working on wiring them up. I want to make this tool as my first project

[@fixinstuff9662]

Holy crap, look at Elio's hand. I know who to call when I need a bolt twisted off.

[@billsmith6555]

You are the master! That's great!

[@jamesbarisitz4794]

Once the new edm machine is installed, you can make some mirror image parts. 😃

[@scottyhankemeier9380]

Holy shit man. That worked good. Nice shop. Ive watched alot of your dent repair videos. Starting work on my Mazda B-Series soon. I may put it on youtube. Thanks for sharing man

[@domenicozagari2443]

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

[@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