Helping a Friend in Need, Modifying a Model A Radiator Shell

[Henry K. Lee]

One of our members had a special request in modifying a radiator shell for a special project he has been building. He said for me to get the apprentice involved, like I do not have him jumping hoops already. But all a side of life a perfect opportunity to show how to cut without distorting a compound pressed piece. These do not like to shrink back well so our tools are our friends but getting in a hurry can make a mess. This all took about 2 1/2 hours.

Lay out with tape as it is a better sliding surface and contrasting color for us old folks.

Air cut off tool as it is more controllable and not so heavy. Key to success here.., multiple passes, not just one but do not cut all the way through. Heat build up, not good for tin work. About four total.

Good sharp right hand tin snips.

[Henry K. Lee]

Cutting away excess metal, not to distort the good piece.

Sanding with a paddle wheel to the tape line.

This just worked out right. My hand step lap forming crimpers were the same size. Sometimes you have to make your own from square keyway stock etc and weld to vise grips.

Multiple passes overlapping as you go will make them smooth.

Cutting a relief to remove the center pointed apex. Hammer down and weld as required.

[Henry K. Lee]

I normally sand blast the area to find minor imperfections when I do high speed sanding that comes next. Really smooths out tool marks.

After it meets standards, re-coat with satin black as it arrived and inspect. Meets standards.

Take your time.., all will meet your expectations and put a smile on your face.

All the Best to All,

Hank

[Les Schubert]

Very nice!

[Harry Lillo]

What is the thickness of your cutting disc?
Harry

[Henry K. Lee]

1/8" Harry!!!!!!!

[Harry Lillo]

Would a 1/16 disc not generate less heat buildup?
Perhaps you were looking for a wider cut with the 1/8th disc to better accommodate your hand shearing.
Well done.
Harry

[BillyBobsSpeedShop]

Turned out great Hank, if you get any pictures of the shell installed and finished please share.

[OilyBill]

Very nice work!