CHEAP & Easy Way 2 Make ANY Bead! NO BEAD ROLLER! - Flow Forming With an AIR HAMMER

[@alleyoop1234]

Bead forming is all fine and dandy, but I instantly saw this procedure for making kustom embossed lettering/script for things like tailgates, door panels firewalls, valve covers, etc..!

[@savage6394]

Came here the same thing! The only challenge I see is figuring out how to make a wide letter and not having it look like balloon letters. Thats where the backer piece might come in very handy, to flatten out the face of the letters.

[@daleskidmore1685]

Yes!

[@fishhuntadventure]

@@savage6394 No dissing this video but yes, that is how it’s done. Not saying I’m an expert but I’ve replicated floor pans and such this way for a while. I’m just not good enough to make a vid like this LOL But I’ve been using hammers and dollies. Need to try the air hammer

[@ohar7237]

I suspect I'll be making some motocross shinguards like this, too.

[@theojilderts9729]

Hhmm.greath idea... Blacksmith theo.jilderts Harlingen.the netherlands..a.studebaker.1955.pick.up.truck Stil.to.restaurate..so...

[@DependableAutoTruck]

you make people who are not interested in metal shaping want to get interested in the hobby

[@jamesenloe2791]

I love how you are getting more confortable on the camera and letting your humor get flushed out. You guys are rocking it out of the park.

[@brianreynolds5246]

Its funny cause I'm sick of the haters it's funny some one that can do something better then some one will bash that person but they started off like shitnor the ppl that bash some one on thier work but don't even know how to do it but still criticize some ones work

[@christopherfeasel6418]

In 100 years guys at car shows are gonna be saying " that's a Karl Fisher firewall, ain't seen one of those in 50 years" How fkn cool is that. Love your stuff man

[@gvet47]

But what do you do with all the holes you put in it? If you weld them shut what happens to the panel?

[@6226superhurricane]

@@gvet47 yep just weld them up and snooth them down. small holes like those are easy to weld without warping the panel.

[@noberet]

You guys are the beading edge of metalwork.

[@joecioe8566]

I would say that was a 150% successful. I love how you encourage people to use your ideas and even sell stuff inexpensively to help others out. Great channel.

[@Tony7190GR]

I wouldn't say ripped off but i have used your ideas on my own car so many times, i live in Australia so ordering products off you is hard but your knowledge has saved me so many times with problems.

[@bryanbrunk1186]

Keep your inside cutouts. You can weld tabs on them and bolt them back in to block off certain paths and create different patterns.

[@joshm8661]

As i always say, you're a metal wizard, and it's amazing what you come up with in your brain on the fly. I'm not even a metal worker, but I really enjoy watching the process.

[@IR-nq4qv]

You could weld different size ball bearings to air chisels to have an assortment of bead roll sizes

[@upyours1256]

yes , cheaper and easier then owning a heap of woodworking tools and lathes , i call thumbs up for your idea !

[@Oneshot8242]

Wow, just wow! This is steel sheet you're forming, yes? I'm amazed at the beauty of the finished product! For series production, you could put one or more of those air hammers on a simple xyz cnc table and churn thode suckers out. I'm getting into sheet work out of necessity, as my 2008 Peugeot 308 needs some rusted panels fabbed and installed, plus about a million other projects. MAN, I love being divorced and retired! Regards from the West coast of Jutland!

[@boltonky]

Don't understand why you don't have massive amounts of followers, i have learnt heaps from this channel over the years and you know how to inspire people to try

[@Ron_Presley]

I think a lot of them are watching hacker Bad Chad to see how not to do things who has no idea to make or build anything like this guy I worked for my long time friend Dan Woods back in the day which was and still is a perfectionist and this Chad guy thinks he is the Cats Meow could not do anything like we use to do. Zero

[@davidhyson9910]

You should be stoked! Body by Fisher did it again. I've seen this morph from your early mdf form, which are still good in my mind. But you've "skinned a cat" with this evolution. And your gift to the community is priceless. I feel Helio deserves a shout out as well. He's stepped up your game, it's obvious.

[@murdoc6501]

Oh man, another genius idea from the mind of Japhands! Love Elio's response to the test run, "(quite) Wow!" Best part is it won't wear out or distort like a MDF/wooden buck would after multiple uses/passes! Incredible results! Go Japhands, keep moving forward!

[@chrisconley8105]

Love the real life trial and error process, great teaching piece, no mistakes, just redirects!

[@frederik32212]

As many people have mentioned earlier in the comments, I would really love to see a video on how you weld up the holes from the form and finish those areas (hopefully with a minimum of warping or having to touch up the bead pattern by hand). That's the part that would kick my ass, for sure.

[@Holmqvist_96]

I've done some panels this way and have had no problems with warping when I welded the holes with a mig welder

[@theupscriber65]

Copper backing when filling holes.

[@smithjohn3080]

​@theupscriber65 came to post the copper/bronze/brass backer makes it waaay easier and way cleaner to fill em

[@BrianFlury]

So as soon as I buy a CNC plasma cutter I will try this.

[@ifixit775]

​@@BrianFluryArcDroid 👍

[@guillaumehumblet2224]

You could try with only the middle metal plate between 2 mdf sheets.. The middle one is the one giving the nice edge, bottom one is not really used cause you don't go far enough to touch it and top plate is basically a guide. If the mdf is strong enough to hold the panel straight, you will save a lot of material, (money for your kits), weight for shipping etc ... if it work people can basically use the matal laser cut part they receive to cut the mdf with a router and a copying bit. Just my product designer mind trying to push the project further :)

[@Johns-t4v]

Ok here goes... IM SURE YOU ALREADY THOUGHT OF THIS, I thought of it when you pointed out the "bottoming out" in the center of the "X". For consistency, I'm sure you could develop a depth gauge that attaches to the gun before the spring goes on.

[@MidYearMitch]

I absolutely love this idea. I have been watching these videos and taking notes for my future projects on my channel. I have a 30 model a coupe that I will need to make floors for and a 48 COE ramp truck project that will also need a floor. I have always loved that X style in panels. Whenever you come out with this kit I will be buying one for sure!! I also make custom fiberglass panels for Corvettes I rebuild. I would love to flow form beads into panels to use as molds to make custom fiberglass floor pieces for my projects. I can see your gears turning in your head and you got mine going as well!! Keep up the awesome work. I love the channel brother!

[@Crooked...]

Very cool! Add your Japhands logo in flowform to the floor of your car! 🤯

[@chriseurton7735]

I want to buy the original bead rolled firewall if you'll sell it. This is an awesome tool, looking forward to buying one! This channel has been huge to me learning, I've been around classic cars and body shops my whole life, took welding classes at a vocational school, welded as a career for a few years, but custom metal shaping had always seemed like something that was unattainable because I didnt have someone to tutor me or a way to learn (at least that was the excuse I made). This channel has changed all of that for me! Keep up the awesome work!

[@jasonboyce9650]

Love your work and the channel. Amazing stuff. Had an idea on how to control the depth at the intersections. Make the air hammer bit ride on top of the 1/4 inch form, instead of inside the bead. That way when you get to an intersection, the bit can’t go past the prescribed depth. Just make sure that the bolts that hold the whole thing together, don’t interfere with creating the bead.

[@JamesMcNamara-j1g]

You have the best hot rod fab channel on any platform. You are an international treasure for actual hot rodders.

[@michaelanderson3771]

Fantastic result Karl. I was of the same thought after seeing you make the rounded air chisel tip a few video ago. I had thought of using a metal form recess even out of Aluminium plate for the edge form and then MDF lower form. MDF upper and Lower plate to act as a stop. I think the Delrin or Nylon rod tip is the key of your tool. The polymer tip being just hard enough without being too tough to marr up the sheet steel panel.

[@lamotorsllc3147]

that looks amazing , my question ,what about the holes you drilled on the fire wall

[@daleskidmore1685]

Weld 'em up.

[@kernowskunkworks]

Exactly, got to weld that lot back up now . Failed !!

[@nathanmanners7862]

​@@kernowskunkworksHow's it a fail, he always intended on welding the holes back up, quick hit with a DA and you'd be none the wiser.

[@13_13k]

My question exactly. Now you have to fill all the holes and grind with die grinder both sides of the sheet metal. I guess it's better than removing the floor pan or firewall.

[@13_13k]

Couldn't you use a real strong electromagnetic force to clamp the forms together instead of drilling holes? Make it work from a small low voltage DC magnet like they use for automatic fire alarm doors. It would jut take a small battery and an on and off switch to engage and release the magnets. No more holes needed.

[@allthings2allmen]

Karl! I will always love your channel and remain subbed forever! It hurts me to say that I've missed most of your videos since my dad passed last November. He really was the anchor for me watching regularly. I will catch up, I learn so much even just observing you here. Man, you are such a down to earth guy and I love how you share things! Your passion is infectious brother!!!Thanks for all you do and the inspiration that you are! Also, a High honorable mention to Elio (did I spell his name right?) He's brilliant & cool!!!

[@MakeItKustom]

Sorry for you loss! And thanks for the support. Elio is correct!

[@allthings2allmen]

@@MakeItKustom Right on my friend!

[@timey1100]

The way you take a concept and transform it into pure mechanical, wow!!! Sheer bloody brilliance mate... I would like ro see fitzee using a couple of your homemade tools, i'm sure he would appreciate he simplicity... Mate love borh your channels always good content. Cheers from down under...

[@maggs131]

A pleasant brain shart. You think it'll turn out a certain way but ends up being more than you expected. I'm envisioning a firewall with a center bowtie 🤘😎

[@paulvanhouts3365]

Hi Carl, I enjoy watching your creativity on the fly. The enthusiasm is contagious. That you make small tooling for the rest of us to buy is really great. Just love the work both you and Elio do. Stay safe guys.

[@Heffel2012]

mind blown, i actually had been working this out in my head, saw your video and now i don't need to like even think about it. just tool up. awesomeness

[@The-Deadbolt-Deputy]

Wow this is awesome ! I can’t believe how flat it stayed and the crisp edges.

[@Northfeather]

Thanks for just being real. The power of loving what you do...is being able to share/inspire!

[@rtrottier14]

that is too cool. I am not a sheet metal guy but this looks fool proof enough that I might be able to pull it off.

[@edog7322]

I love the way your mind works. I get excited with you like I’m out in my garage loving life. Keep running in to problems scratch that keep running in to solutions. Your in your flow.

[@burtonr]

That's cool! I like the idea of that "X" being just a part of a pattern. Making a "T, and other common shapes in small sizes and just piece together some nice custom beaded panel. Also a good idea from another comment about keeping the inner cutouts to be able to create different paths.

[@thedukeofspeed]

that is badass.... I need something like that for my race car production..... Very good young man !

[@dougsmith1622]

You have some great machines. I am where you were in the beginning. Your genius is your love of experimenting!

[@jasone3166]

This is just what I was looking for. I want to make a faux firewall so that I can put some Dynamat on the inside of the actual firewall and then put the faux firewall over that so it looks stock on the inside of the car ('28 Pontiac), as well as the outside. Thanks for the idea! I think the center of your X bottomed out because you go over it twice as often as each arm of the X, as well as the reason you mentioned. You have a good idea to do the arms first and then do the intersections last. You're awesome!

[@SheetMetalShaping]

Boom! You guys are doing great with the air chisel line of tooling!

[@monadking2761]

I made something like this out of wood for the bottom panel of a door that needed releaf in certain areas. Clamping the wood on the top and bottom keep the metal from walking too. Back in the 70s, I used to install factory sun roofs into high end cars and learned by clamping metal on both sides, I was able to move the metal well in a controlled fashion. Great job using the metal as dies.

[@BigBoxDodge2020]

Never stop learning which helps to expand your capabilities. Nice tool work, dude.

[@mixerman1]

It really looks great. The only negative I see is all the drill holes. On your car copper rivet plugs in those holes would look killer. Always waiting on more

[@danielbuckner2167]

Just use some brass or copper as a backer and weld em up

[@jeremyhanna3852]

The other thing is you dont need a cnc to cut those hammer forms can be done with grinder & hole saws and good set files

[@conover1978]

I’m digging your hero hair! Master fabricator! 4:09

[@mikerosolack2837]

Wow sir I am 63 been doing this thing for a long time, you are so impressive. My hats off.

[@rootnpearl]

Sweet tool. Keep it going.

[@conover1978]

6:15 THATS AWESOME ‼️this is why this channel is the very best!

[@conover1978]

5:28 pure genius hard at work. I think ideas like this is what makes the world great!

[@larryreece1403]

So great to see this success! I remember in the class in Vegas you were trying to figure this out.

[@MakeItKustom]

Ya! This is the best way I think now.

[@RR-mt2wp]

Great transition to a fantastic tool I wondered if a male end welded to the hammer bit "bolt" then female plastic screwed on would be easier for those without lathe or heat. Fantastic it worked so well.

[@DoggofDoggs]

Fascinating how you thought-processed this idea, and props to the video production because this all came through. If you could only eliminate the holes in the piece. One idea would be to use a table with several "rollers" that could tightened down the guide plates and the work piece. The rollers could be loosened and moved one at a time as you progress with your flow work keeping the plates and work piece from moving. You are rockin with your creativity.

[@Joesrustbuckets]

great job Guyz, Love it when you said I don't need a Pullmax now. lol 🤘

[@pieteri.duplessis]

What a nifty idea. Very well done and fun to watch. All the best.

[@davidgalea6113]

You make such good content, these diy without fancy tools are my favorite.

[@seanglover6781]

Loved the idea. One idea is to add more holes in the form then fill in the holes on the firewall with rivets.

[@stevenoe6395]

Hell ya i had that idea after i watched one of your videos with using mdf a year or two ago i just never got to doing anything with it to buisy with work and always seems like something happens before i can start a project and it never gets done lol good to see it works!!!!! Thanks for the video!!!!!

[@tsaincic01]

Hi Karl (and team), this is awesome. As I mentioned to you a while back on email - I had my steel jigs made here in South Africa to help me fabricate new floor plates for my F250 project, based on the wooden ones which were not that successful for me. A bead roller cost and to import replacement floor parts from USA was too costly. I can send you pics of my test run -.... now I just need to learn how to dial in my small gasless MIG to close up holes. But I further see the holes do not need to be so close and as many as I have in my design. I truly am honored to learn these things form you.

[@tsaincic01]

I used a hammer flat head, welded to - A tapered cap screw head which I cut off and "rounded", then welded this onto the flat head portion of the hammer shaft as purchased.

[@MrSociallyDistrted]

Great to see you took it to the next level. Makes a ton of sense and the outcome shows. 🏆

[@danielkruk212]

To reduce size of air hammer bit…. Chuck up shaft, “mount” air angle grinder on tool holder and let it rip. Accurate enough for this application

[@idyllic2210]

Dude this is innovative and it couldn't have come at a better time because I just cut the rear wall out of and old truck im building and had been trying to figure out a way to reinforce the new wall. Im excited for you the finished product is unreal ! Thanks MIK

[@PatriotGadget]

I enjoy watching your creative process. I also tend to brainstorm in real time. If I hit a roadblock, I stop and look for a detour. Just keep pressing.

[@9FingerFabrication]

Such a great thing! Really gets the brain gears moving.

[@stevephillips8719]

WOW! I am building my own to put the support ridges in the new belly plate for my Audi Allroad, (having totally destroyed the factory one on a '4WD only' track last weekend). I love this channel!

[@The-Deadbolt-Deputy]

Carl, I enjoy the way your brain works. What an awesome concept

[@johnvanhorn3208]

Another great day 🎉

[@davidmcgee1413]

Dude!! That’s super cool. All of the stuff is stretching metal, your buck and air hammer setup sets up some fantastic control to keep everything square!!

[@EnriqueGonzalez-iu3so]

Fantastic video! I love the way you did it! Have you tried using double-sided tape instead of making holes in the metal sheet? Greetings from Mexico

[@Berend-ov8of]

I Like !!! You could CNC a signature profile you can just in situ add to any car you customised. Simple is genius and this is so simple. I love watching the process of this thing happening, all the way from nothing is certain, to will you look at that ! It really is flowing. It's almost like you're blowing up a balloon. You just gently let it sag into shape, 'cause the biggest risk is overdoing it. And it staying so flat is a nice bonus. Beautiful !!

[@MarkEmpson-bf8mn]

Absolutely exceptional guys!

[@JAcustom1]

Good job, this method was one of the reasons i bought a plasmatable. You can trust a steeledge holding its shape. This is the most fun part of metalshaping

[@allengeringer574]

The best part is this- it works with 3D printed jigs as well. That's a game changer.

[@Chaindriv3]

Making these kind of tools and sharing it is awesome. Thanks!

[@alanpaulick7815]

Well done Karl. You're on another level when it comes to fabricating. Take care.

[@wyattoneable]

Wow. Perfecting your skill with better ad better (self made) tools is pretty impressive.

[@JamesErd]

That worked even better than expected 😅 I really like this technique. None of the edges looked over stretched or too sharp. I might still bust the edges on the bottom form. To prevent the tear out on the delrin I would recommend busting the top edges of the guide plate with a flap wheel leaving no sharp edges to damage the tool. For the tool itself it probably makes sense to mold it in hard polyurethane. More easily to scale up and more durable than the delrin. If I was just making a few pieces for myself I would switch up to glass filled delrin for its resistance to shattering and it would probably be more resistant to wearing and gouging.

[@daleking8529]

What a slick idea!!

[@kevinmaxwell6610]

In the back woods area where i live, we all have one or more rider lawnmowers just sitting in the yards. Most of those mowers run great but have a rotten mowing deck. It's kinda amazing and funny to see the strongback X is the only thing left sometimes. I needed to strong back my patches but couldn't figure it out fast enough, so i used 1" angle iron. Dam, i have air hammers and wish I would have seen this video 3 years ago. I bet those patches would still be here un corroded like that angle trap i made 😁 . Cool video. Thanks for sharing your studies. I appreciate it 👍

[@Frollicking_Gurnard]

What an awesome kit mate! I love the way you're always thinking of making "expensive" workshop techniques accessible to the common man. Could you add a depth stop to the forming tool as well? Like a skirt that slots on to the forming tool and runs against the bead form so you could set a certain depth and would get a perfect depth all the way round.

[@hawaiiandragon76]

GREAT IDEA!!! Looks great, you could make a flared part on the air tool as a hard stop, to control the depth of the bead

[@briankinnear7461]

Great job on the bead maker. Fantastic concept. Endless possibilities. Be safe and stay well.

[@michaelhallas6450]

Look it forward to see the new tooling on the bead rolling . 😊

[@ddoherty5956]

You are a fantastic Ambassador for Canada Karl. All the best 👍🇬🇧

[@TheRolfano]

You are so talented! I admire the way you solve problems.

[@sethhughes2163]

Hey Karl... picture this : grab some 5/8" or thicker plate or barstock, go to the mill, grab a ball endmill, cut your design to the depth of the radius of your endmill, cut interlocking " T " shaped keyslots to add length and line them up, effectively creating a die and use your delrin ball tool like this. I could spell it all out, but you get the idea. The plate you groove can be a tough plastic or whatever. To locate the design just burp the air hammer in each corner to locate, set weights on it to help control movement. Just a thought my friend! Love what you do! Respectfully, Seth

[@geoff3656]

Yes I was where you are now 5 yrs ago making the form with angle iron. I’d make the shape fit the box section I needed to copy ( Alfa Romeo suspension leg indents ) Then using dome headed chisels and heavy hammer stretch the material to the depth of the angle-iron former.. Very easily. I even did indented pyramid shapes as was originally designed. The addition of an air hammer is genius and a lot quicker… easy to free form too ..!! Thanks I’ll incorporate that air hammer for sure 👍.. I mig tacked the angle-iron to the work piece .. no holes or bolts 😶🫥so was invisible. If you round the edge of the angle iron you get a radius curve too.. Cheers

[@blainekoch5018]

Karl strikes again. Well done sir. I wish I had the time and money to come and work with you. You are a truly talented individual.

[@MH-rb7lp]

You need to try this on a panel not laying on a table before getting too crazy. Not saying it won't work but a panel free hanging may react differently than one on a table.

[@macthevan]

Your one hell of a clever dude love watching you make things

[@kellymonday6137]

Very awesome work my friend 👏 Things like this is how Foose and others became "Famous". The little touches.

[@elvislive1557]

Sweet new tool and fresh ideas to age old metal working! I'll take the first model a floor pan tool!

[@JamesErd]

And then when continued watching I see you that you’re not leaving sharp corners 🤩

[@fazyluck]

That's a cool and interesting way to form it! Good for repetition

[@airecraft1]

That’s ingenious, nice job

[@bruceaskin9645]

Suggestion, double up on the top plate , so the bit is less likely to jump out. Assuming thats how it got damaged. You could also harden the tips.

[@paulmasson9674]

Cool stuff! If you didn't want to bottom-out, you could have tabs/ears or something on the air hammer tool part to touch the top of the plate to limit how far the tool goes into the groove.

[@curtbelshe]

This is brilliant. I’m going to try this out. Perfect final firewall.

[@williamenglish4398]

I love what you're doing very inspiring.What you could do with your backing plate is to thread the holes in the backing plate so you don't need the nuts on the back of your studs.

[@hickeyskustomresto]

I gotta do a custom floor for a '56 2 door wagon. This is gonna be the way. Well done. I'll have to order some of your bits and Delton tips

[@pukinpaja1974]

You really are a metal wizard! Nice work and greetings from Finland! 🎅🏻👍🏻🇫🇮🔧

[@123gonow]

Pretty slick Karl !