Reminder of some good tips.
We fabricated a new one for our Saab c900. Much simpler design than yours though. Old and new:
For metal shaping it's really helpful to have a metal bender. Many folk on here have made their own and there are a few threads on them. We used the instructions by bmwtony on retro rides and have used it endlessly. It's also a nice practise welding project. His whole panel making thread is worth a read but the metal bender plans are on this bit:
That's his btw. Our is rather more rustic.
We used a sheet metal hole punch to make the holes. Happy with the tray, but kind of wish we'd done it in stainless steel.
That whole thread is well worth a read I agree! The metal bender is on my to do list, it’s so simple but versatile and clearly effective.
There are a few things I wished I had done before starting my car restoration. One was buying a Black and Decker powerfile as it has been the most useful allround tool. Another was making the metal folder - it folds metal, it's a vice, it's an anvil... So many on here have made them and said how valuable they were, but it wasn't until we made one that I realised what a boon they are for all sorts of jobs. Wish we'd made it on day one. Getting cut off bits of bar, angle iron, cylinders etc is helpful too when you want to form shapes.
Ok, I'll ask the stupid question, which bit of that folder move to make the fold! Can't visualise it.
This. Or a selection of hammers depending on what you’re bending.
So it is not a folder, just a very wide vice ?
I suppose it is in principle, a bit more versatile though.
Yes, I see that now - it has a very deep throat ( ooh er missus )
for the OP you could make a "Negative" from ply or MDF and use it as a hammer form, you'd probably get one or two out of it
Mk3 & 4 Ford escorts rot through the battery tray and straight through the bulkhead. readily available as a repair panel. Just unpick the battery tray off the bulkhead panel underneath. Saves making one unless you need it identical as the original.
I replaced dozens of these back in the day. Always supplied a battery cover as a freebie (I think they were a quid each!) to the customer when I did. It stopped the problem reoccurring.
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