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In this episode I fabricate sheet metal brackets that go underneath the headlights to support the turn signal housing and small horn grill. Porsche sheet metal fabrication from scratch isn’t the quickest way to build a car by any means. Having said that, I try to avoid buying aftermarket parts that are not a good value. As a matter of fact several people told me that the expensive aftermarket backdate kits need to be massaged to fit anyway. As a result, I will show you how my homemade brackets transform these 74 fenders to a 69-73 longhood look.
Porsche Sheet Metal Fabrication using a Pexto Bead Roller
To get started, I began with some cardboard templates and some flat sheet metal stock. Next, An old Pexto bead rolled the curved edges on the flat sheet metal to make the bracket that supports the turn signal housing and front grill. So, I formed these parts as accurately as I could based on the shaped of the OEM parts and factory original pictures.
The video shows temporary rivets that hold the various sheet metal parts together prior to final welding. The fit up of the various sheet parts is important especially in complex corners. Hence, the more clamps and Cleco’s you have the better. Therefore, I highly recommend the kit linked below:
Cleco temporary rivets
https://amzn.to/2JxZRjt
Sometimes a special form tool must be made to shape the detailed depressions like the factory did. Therefore I shaped some heavy scrap pieces of steel to make a forming tool. The formed piece that lives between the horn grill and the hood is a good example of a part with some intricate bends in it.
Thank you for checking out this website and enjoy the video. Also feel free to leave a comment if you have any questions. Thanks for watching!
I love your tip about using cardboard templates. That seems like a good idea to prototype. I’ll have to consider your tips when it comes to steel fabrication.
Thanks Bob! Some people joking refer to them as CAD templates. Cardboard Aided Design 🙂