Well today we finally started work on the tub for car 2, we first thought the sheets would be 10 x 5 but we ended up with 8 x 4 so got 4 sheets. one would make the rear wings and rear tub sections.

So, Step 1, nice clean sheet of metal :

Step 2 : a trip to the plasma cutter, we have the 2 parts for the rear wings :

Step 3 : cut in some details for the shape

Step 4 : Put an initial bend in from where to start the radius

Step 5 : Put into jig to form radius and bend

Step 6 : Add additional details such as the top bend and the semi circle for the window section mounts.

Step 7 : Using a wooden template of the wheel arch mark out the returns needed and cut, then clamp 2 bits of wood either side of the sheet to form the arch and returns. Bash with hammer till they follow the shape.

Step 8 : Remove the wood and then check with eyebrow and against existing tub

Time taken to create 2 wings, 5 hrs 30, this included setting up of all equipment, taking measurements, making them and packing away afterwards. All in all not a bad way to spend a Saturday afternoon.

Updated – Tuesday 16/07/2013

As part of the same sheet we planned to make the 2 rear quarter panels for the lower tub section. In lunch time Monday this is what was achieved:

Section of sheet cut down to size, marked and the radius cut out:

Then all bent up and offered up to the rear wing.