Thread: I couldn't build it for $3 K either!

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I started by making some patterns from cardboard. I like to use tablet back type cardboard. It's easy to cut and it gives a better indication of what the metal will do. If the cardboard won't bend to fit easily then the metal is going to need persuasion.

The back piece is flat. No problems there. The side piece needed to be formed to fit the complex contours of the cowl.

First I "cupped" it slightly. I used a medium ball peen hammer and used my vise as a "shot bag" to support the metal. Open the vise slightly and work the metal in the opening between the jaws. The object is not to beat the hack out of it either. Just work it using not much more force than the wieght of the hammer. I used my hand to hold the piece while I formed it because it didn't take much effort. I don't recommend whacking your fingers.

After I had it cupped I tacked the back and side together. Then I heated the top of the side piece and wrapped it around top of the back piece. You'll notice the slight angle on the top of the side piece. That was needed to get the two pieces to mate up when I made the wrap. I figured that out with the cardboard.

After I rolled it there was a gap in the front. I knew that was going to happen. I heated the area and used a cresent wrench as a forming tool to gently work the edge into a curve. Kinda like working the bill on a baseball cap. I had to do this a couple of times to get the fit right.

Then I buffed the piece up with a belt sander and DA sander used as a grinder.