Glad to be a part of the Kustom Crew, it's a small way to give back for sharing your skills on fabricating and body work! I hope that other people that are getting something out of it will join and support you as well. Look forward to the next segment on the Zephyr. Take care brother!
Love that you're back on the beautiful metalwork! I think your more casual projects are fun, but I always learn a lot from the intensive metal forming and welding videos! Keep it up.
Morning Karl, the bead roller dies you made the first time, you can repair them by boring out the drilled hole, install a pre made bushing & re-bore... that's one thing I've definitely learned, is how to fix my screw ups!! I bought some Dies from Eastwood, I think the Dies you made are in the box, I will look when I get home.
Yeah, definitely they could be repaired that way, but the diameter was still too far off. I am still going to keep them around though in case I can use them at a later date.
It's admirable you strive for perfection but those tiny imperfections are the difference between hand made and machine made. You do your best and be proud.
Second time is as near perfect as any man could be and on dies' made in house . Your work ethic is an insperation to be proud of and I am sure to all of your followers .A shout to Butlers who cherish you by sending first rate product to express there appreciation .Can't wait to see more. Stuart in Ontario.........
Karl I am so sorry to inform you that I do not have a Telegram account. I do not have a cell phone as I am just an old man with a computer who watches videos of people who have incredable talent and a expression of total mastery in there craft. You sir are one of those who I admire as you not only have patience and a willingness to see a project to fruition but also the patience to teach others as you do . Thank you for your invitation, I am overwhelmed with gratitude and will continue to watch your videos and learn from someone who clearly explains each step. God Bless you and yours in this new year, Stuart in Ontario.............
Good to see someone who actually measures carefully, and takes the time to correct mistakes. It's always better to just use drill bits to get close to the finished size, and finish out with boring, or reamers.
Jap Hands, you are a champion teacher. I am not a restoration type but keep coming back to your channel for the little tips and tricks you drop in every video. Not to mention your obvious passion and love of what you do. Bargo NSW Australia
I love that you show the details how you do something. My 19 yr old inherent a basket case 1974 beetle, that needs a lot of panel work (rust). You videos is giving me the confidence, We can do it. Now we just need to become a better welder. Thank you very much.
I've been wondering why the work with the Lincoln had halted! I feared that you had started taking on too many projects, losing focus, but after getting your explanation I fully understood why it needed a break. Wooow, you¨re making those dies manually in the lathe!!?? I'm shocked with awe! In shop class at school we joked about being able to do it, just making it a distant dream. Thank god for CNC when it comes to what I'm able to do, but you sir, are a legend!! I'm gonna skip right on to your next episode now. Thanks for uploading! Greetings from Sweden
Amazing talent. Love that you take the time to explain all the details of how you you make parts, the little ins and outs of details. Im learning so much from your videos. Thank you for sharing.
Great stuff Karl. "This piece is as good as it gets, but I gotta try another idea that might work better. That didn't work quite as planned so I'm going to make a 99.99% perfect piece just because I thought of a small tweak that should improve it." This is the thinking that advances your craft and will pay dividends for the rest of your life as an artist. Your thought process more than anything keeps me looking forward to your next video. Thank you.
Karl, loved how you stepped back from this and assessed the problem at hand and figured you didn’t need to scrap the panels you already spent so much time on. I really enjoy learning techniques from you, but sometimes you can learn more from watching someone’s thinking process. Great work and I can’t wait for more on this project! Cheers!
Sure is the right way. When the man is not happy he sure is not happy. 99% is not good enough. That's true professionalism and true determination to do the job right. This man sure does keep going, whether it be 2-3-4 times until its right. We all can learn something from Karl no matter how good you think you are. Personally I true admire and respect this young man for all the effort he puts into the work and productions and of course we cannot forget Elio a true companion. Those new welding gloves look great so I must pay a visit to the site.
You know you've found a good channel when you're only 1min in and already clicking the like button as you just know that you're going to enjoy the video!!
I hate TH-cam, I haven't received any notifications for your videos. So now I have to catch up on the zephyr project... Which ive been waiting for since you found, bought, and started, put on hold to move your life, and now have started again. Love your videos, and the contagious attitude and work ethic you bring to the table. Keep'em coming I'll be caught up soon.
I appreciate your good work. It's really encouraging to see you stop and think through a problem. Many of us just figure guys with you skill set never have the kinds of problems or blocks that we do. I see that you do and its helpful to watch you resolve those issues. Keep up the good work. You are a natural and highly skilled teacher. Every episode is a master class.
42:41 It might be easier to cut a flat strip of metal and lay it across the body line and check for flats or waves. I'm an apprentice die maker working on body dies, and that's something we do to check for continuity on curves and shapes after grinding/welding. For shorter spans we use banding straps or flat mahogany strips and brush on something like Dykem's "hi-spot blue" which shows every imperfection. It's quicker than applying layout blue and scratching it to check for high spots, which is also a viable option. Thanks for the videos, I've enjoyed seeing your processes. It's inspiring to see you build this stuff from scratch, keep up the good work.
Always nice watching a Sculptor work ... (like watching an amazing street performer) Teaching the details you look for in your work/passion are invaluable. Nice seeing how you have the time and inclination to test two different methods also on one already 'almost' perfect piece .. Perfection can be a curse 😄
Do I think there is a better way???? Karl, you're very kind. This is simply awesome. Every time I watch one of your great videos I feel blessed you are so willing to share. Thank you so much.
awesome dogs, Karl, and always enjoy watching you build and fabricate. Glad to see you getting back on the Zephyr! It's really shaping up. Glad it's starting to flow again for you on it!
Hey Karl, great video and thanks for bringing us along. One of the most precise ways you can cut that hole is with a boring tool in the tool post. You actually seem to have one in your tool post that you are using for facing and contouring. If you set that boring tool up on the center line you can cut a very precise hole. It’s called a boring operation. You remove material from one side of the cut and it’s super easy to get a round hole. Just plunge a hole with a twist drill large enough to get the boring tool in and then open it up to size.
Karl, the best way to do large holes is to drill to one size smaller than you want and then use a boring small bar to finish them to size. That way you are not at the mercy of the drill bit to get a straight concentric hole. PS: me thinks by the look of it that maybe you should take a day and give your lathe a little TLC, a little cleaning, and maybe even painting, never hurt anything. 😁
That first piece would have been welded on 99% of the time. Your desire to make it as good as possible is what makes your channel awesome. I found your channel through a friend sent me a link to one of the episodes putting hydraulics in the caddy (I've got a 61 Impala with front hydro that I'm getting ready to do 4 wheel on) and been hooked from the first video. Keep the killer work coming man!!
Glad to see a video on the Zephyr. Been awhile. Thanks Karl. Your a perfectionist. Brent started a project that you might go over a day or two and help him. Thank you for sharing!
I'm so glad you are back on the Zephyr Karl. One of the most beautiful cars ever made in my opinion. Your fabrication skills, good eye for design and talent made that body line look easy. She is starting to flow nicely to the back to one of the most beautiful car rear ends in automotive history. I'm looking forward to seeing this one finished. Thanks for all the efforts Karl. Great work!
Love the cab over a ton but I'm really glad you're back on this Zephyr project. Actually I learn a lot from all of your videos, however, this body style is so desirable. I think we should call you Professor Kustom because of your teaching abilities. Oh and again I( love the editing and music, perfect.
Karl, I’m sure you are aware of them, but just in case you are not, annular cutters drill a more precise hole than standard twist drills. I use them in my mag drill and the hole quality is superb. I know you can get adapters for them to fit a Morse taper. So you could use them in your mill or even possibly your lathe.
A drill will never give you an accurate hole. Next time drill undersized and use the boring bar you have to finish to size. If you don’t have a way to measure inside dia make up a test bar to the size of the bead roller and use to test fit.
This is why you’re the best brother! Most people would have just used a little bit of body filler to smooth out those minor bumps but your relentless pursuit of perfect metal just wouldn’t allow it 👍 great vid, i with I had your lathe! Tell Brenda I says happy 2023! 😍
It is amazing to how much one little piece a few feet long can take to form. And what does he say you're not done with it yet you have to weld it in. Of course anytime you weld something there's still some forming. Fantastic video able to learn some things without feeling like I'm sitting in a classroom. Interesting and entertaining. Thanks for taking time to make the episode
First I salute you for being able to make dies that match an existing contour. Nice coordinated hand-wheel operations to get the shapes you need. I was also impressed that you bought two blanks. I would have bought a foot of stock, and probably needed most of it :) But I do mostly CNC now, so it comes out perfect quicker, and I can make 1 or 1000 with no sweat. However, for concentricity and precision, drill undersize and use a boring bar to get the exact size you want. Using reamers and using boring bars are precision operations, while drilling even with a new drill on a mill or lathe is not. I know it is an old lathe, but please cover the ways when using sanding or grinding tools. That dust will eat the ways up on the lathe in a short time. Wow, someone that knows how to read vernier calipers. I continue to be impressed.
I was repairing some 69 VW Squareback fenders and between you and Fitzee I was able to figure out how to do it. Just below the headlight buckets the metal was like swiss cheese. The fenders had 6 different radiuses and then there was the style lines on the fender, and a spot-weld flange for re-attaching the headlight bucket. I had tried to make the part in one-go, but it never turned out right. Then I saw how you were going to make the style line on the Zephyr and then weld the rest of the panel to that piece. So, that got my brain turning. Then I saw Fitzee's Cut-n-Butt repair video and that did it. I prepared the internal spot-weld flange by hammer forming, then cut it up into threes. Spot welded the pieces into place and then formed the radius it needed. I still need to practice more, but my fender dilemma is done thanks to you and Fitzee.
One of my favorite videos you have done. I like that you try new techniques. Even though it didn’t work, I like that you showed the process of cutting the arch then trying to form it. It seemed like it made sense. Thank you.
Happy Karl, I wish you, your family and friends a prosperous, healthy and safe New Year. The Zephyr is a great start, happy to see you back on it. I think it will be a real gem when you are done and I love their shape. I love your creativity and skill set, which just keeps growing as you share that journey with us. Good on ya mate!
Brilliant work. As a machinist I sympathize with drill bits wandering a lot. To fix this we always drill undersize and follow up with an on-size reamer, it provides a cleaner and more precise finish 🤘
Jay the Florida pool pump motor repair guy. When Service Calls Longwood approved ! that was good info 2 see& know👨🔧looks cool, good job !! Make it Kustom
You show great restraint and patience to go for the second iteration of the strip rather than settle for the first. that seemed to work okay but perhaps not good enough. Great work and presentation Karl!
Karl, I so admire your meticulous attention to detail. I myself get into a project with the best of intentions and then am like, "gotta get it done!", and detail kinda goes by the wayside. Wish I had your patience. Also, I will be paying close attention to your 3 window fabrication because I have a 5 window Plymouth Coupe that I plan to build into a three window, and want to finished it for Winfields next show. So thank you for the glimpse into your minds eye, and I'll be watching and learning as you go. "Hep"
Hey Carl, your apprentice and cameraman is doing a great job 👍 Also, You do amazing work Carl, plus, your humble, smart, and a really cool guy 😎 Your headed to legendary status like "Lead Slinger" from the 50's & 60's. He worked on builds the old school way with that fatty cigar in his mouth and did it through his 80's. You have the same cool build style as the Legendary Lead Slinger, so awesome Carl!!!
Good job. I watched Lazzy put 2 dies side bye side on the bottom shaft of his bead roller and it made a step notch and he used the notch as a fence on the die itself. That way you can bead roll long swipes and the roller die work as the fence. I hope that makes sense. That's how he showed me how to make model A rear corner panels. It works pretty good and I think he even sells some of his dies with a shoulders machined on the die so you don't have to stack dies side x side.
You should totally invite Fitzee to come work on the zephyr with you for a couple days! This is right up his alley, I’m sure he’s watching intently too!
if you want to see if there's a flat spot in the new panel when you make the other panel flip it over and lay them alongside each other than you'll be able to see any flat spots easier. The lines are looking good Karl. Your getting there, keep it up.
Interesting piece to make, it looks good out here in monitor land and I am sure in the shop it does too. Thanks for the lesson. Everyone has a way to do things and it is always great to see a different way.
Karl, here's a way to ensure that future bead rolling dies have round holes in the center of the dies, but it may be more work & accuracy than needed depending on the use (other than bead dies): Start with a spotting drill or justcthe small tip of a center drill to keep your first drill close to true center. (Also remember that twist drills don't usually drill round holes.) Step up in drill sizes (like you do), but keep the hole undersized enough to be corrected with the largest boring bar that fits. The boring bar will correct a hole that's off-center to be back to truly on center. You can finish a bored hole with a reamer if you need a really good finish. I'm not a professional Machinist, but I believe that this is the proper procedure to ensure a hole is actually where you want it. Another possible reason for the problems you discussed could be the accuracy of the two shafts on the bead roller where you attach your dies. If they aren't exactly the correct diameter, or if they are worn, that could be a source of what you see as oblong discrepancies in the parts that you bead roll. I'm not trying to find faults with what you do - I'm just trying to offer possible ways to improve future parts made on your lathe & offer, from the peanut gallery, possible sources for the less than perfect to your eye parts that you see as being caused by oblong tooling. I am always amazed at what you make in your workshop just by using your skills & tooling that you design & build in your own shop. Definite thumbs up!
Boy, I'm glad you're in charge of production. I would hardly have noticed the lumps, let alone put myself to the trouble of ironing them out. Might be the reason I haven't been able to flip the last four 1939 Lincoln Zephyr 3w Conversions I've done. Seriously though, your design decision-making process is so exacting that what comes out is always spot on. And I really like that you have Elio to sound off your ideas on - really brings us into the conversation too, I reckon.
I've seen some guys run the sheet metal through a planasing hammer on the same area that you wish to bead roll first, must just thin the metal ever so slightly to help the bead rolling process. keep up the good work brother.
Happy new year karl . Great to see the zephyr back into the playlist , very gratifying to see a finished part that meets your exacting requirements. The attention to detail goes above and beyond what most would be happy with . Looking forward to seeing you welding those on and bringing the body further along towards completion . I'm surprised with the dies you didn't just pop them back in the lathe and use a boring bar and then add a new centre spacer . Thanks for bringing us along on the ride tho very good evening entertainment and just an amazing way to learn something .
With the very few patch panels I have made, I always found a better result when I made the part bigger than needed. Everything seems to flow better and line up easier. Good call on this one!
YES! YES! YES! Another great video from Karl the Kustom Kreator. Love your work always Mate. I was so waiting for this post so much. Billy J...... Queensland, Australia. 🚑🚓
I'm in the middle of my first attempt at major body sheet metal mods. One thing I did, though, when I pieced in another panel was to radius the corners of the patch piece, rather than a sharp 90 degree angle at the splice point. I did a large radius at the corners.
Killer job with the dies and panel! I was thinking earlier at today that when there will be the next Zephyr video? And here it is! Keep up the good work!
i love your channel content i started watching you then brent on halfass kustoms and love his channel too. both excellent choices really great channels. Thank you i learn so much from you both great teachers..Very Skilled and Creative
In today's instant gratification society, I REALLY appreciate the degree of detail You share with Your work Karl. Top shelf, Thanks!
Glad to be a part of the Kustom Crew, it's a small way to give back for sharing your skills on fabricating and body work! I hope that other people that are getting something out of it will join and support you as well. Look forward to the next segment on the Zephyr. Take care brother!
Thanks so much for your support. Cheers!
Amazing work bud watching from Edinburgh Scotland ❤❤❤🏴🏴🏴
Love that you're back on the beautiful metalwork! I think your more casual projects are fun, but I always learn a lot from the intensive metal forming and welding videos! Keep it up.
SCAM?
A makeshift pattern follower for your lathe can be a simple addition tool in the opposite side of your toolholder.
Making it custom way is always the right way Carl you've got a special talent and a special eye for see Everything the right way And the right look
Morning Karl, the bead roller dies you made the first time, you can repair them by boring out the drilled hole, install a pre made bushing & re-bore... that's one thing I've definitely learned, is how to fix my screw ups!!
I bought some Dies from Eastwood, I think the Dies you made are in the box, I will look when I get home.
Yeah, definitely they could be repaired that way, but the diameter was still too far off. I am still going to keep them around though in case I can use them at a later date.
Your attention to detail is what craftsman, are made of. Excellent job 👍
It's admirable you strive for perfection but those tiny imperfections are the difference between hand made and machine made. You do your best and be proud.
Mad lathe skills! Thank Elio for the shots of you running the controls while you made the Dies.
Will do Larry! Glad you like that bit
Second time is as near perfect as any man could be and on dies' made in house . Your work ethic is an
insperation to be proud of and I am sure to all of your followers .A shout to Butlers who cherish you by
sending first rate product to express there appreciation .Can't wait to see more. Stuart in Ontario.........
Karl I am so sorry to inform you that I do not have a Telegram account. I do not have a cell phone as I am just an old man with a computer who watches videos of people who have incredable talent and a expression of total mastery in there craft. You sir are one of those who I admire as you not only have patience and a willingness to see a project to fruition but also the patience to teach others as you do . Thank you for your invitation, I am overwhelmed with gratitude and will continue to watch your videos and learn from someone who clearly explains each step. God Bless you and yours in this new year, Stuart in Ontario.............
Good to see someone who actually measures carefully, and takes the time to correct mistakes. It's always better to just use drill bits to get close to the finished size, and finish out with boring, or reamers.
Karl, your never say good enough attitude is inspiring. Thank you!
Jap Hands, you are a champion teacher. I am not a restoration type but keep coming back to your channel for the little tips and tricks you drop in every video. Not to mention your obvious passion and love of what you do. Bargo NSW Australia
I love that you show the details how you do something. My 19 yr old inherent a basket case 1974 beetle, that needs a lot of panel work (rust). You videos is giving me the confidence, We can do it. Now we just need to become a better welder.
Thank you very much.
I've been wondering why the work with the Lincoln had halted! I feared that you had started taking on too many projects, losing focus, but after getting your explanation I fully understood why it needed a break.
Wooow, you¨re making those dies manually in the lathe!!?? I'm shocked with awe! In shop class at school we joked about being able to do it, just making it a distant dream. Thank god for CNC when it comes to what I'm able to do, but you sir, are a legend!!
I'm gonna skip right on to your next episode now. Thanks for uploading! Greetings from Sweden
Amazing talent. Love that you take the time to explain all the details of how you you make parts, the little ins and outs of details. Im learning so much from your videos. Thank you for sharing.
It's like watching a skilled Badchad. So glad I stumbled on your channel.
Great stuff Karl. "This piece is as good as it gets, but I gotta try another idea that might work better. That didn't work quite as planned so I'm going to make a 99.99% perfect piece just because I thought of a small tweak that should improve it." This is the thinking that advances your craft and will pay dividends for the rest of your life as an artist. Your thought process more than anything keeps me looking forward to your next video. Thank you.
Karl, loved how you stepped back from this and assessed the problem at hand and figured you didn’t need to scrap the panels you already spent so much time on. I really enjoy learning techniques from you, but sometimes you can learn more from watching someone’s thinking process. Great work and I can’t wait for more on this project! Cheers!
SCAM?
@@dennisschickling2249 most definitely!
Sure is the right way. When the man is not happy he sure is not happy. 99% is not good enough. That's true professionalism and true determination to do the job right. This man sure does keep going, whether it be 2-3-4 times until its right. We all can learn something from Karl no matter how good you think you are. Personally I true admire and respect this young man for all the effort he puts into the work and productions and of course we cannot forget Elio a true companion. Those new welding gloves look great so I must pay a visit to the site.
I love finding old videos I've not seen before & this one's a gem! 💚🇬🇧🌱 Really want a lathe, considering building one as my first project of 2024...
You know you've found a good channel when you're only 1min in and already clicking the like button as you just know that you're going to enjoy the video!!
Good old trial and error comes through again... I think you're on the right track there. Good job!
I hate TH-cam, I haven't received any notifications for your videos. So now I have to catch up on the zephyr project... Which ive been waiting for since you found, bought, and started, put on hold to move your life, and now have started again. Love your videos, and the contagious attitude and work ethic you bring to the table. Keep'em coming I'll be caught up soon.
I’m so glad I have my Pullmax. It makes my life so much easier. You do such fun work and you’re good at it.
I appreciate your good work. It's really encouraging to see you stop and think through a problem. Many of us just figure guys with you skill set never have the kinds of problems or blocks that we do. I see that you do and its helpful to watch you resolve those issues. Keep up the good work. You are a natural and highly skilled teacher. Every episode is a master class.
42:41 It might be easier to cut a flat strip of metal and lay it across the body line and check for flats or waves. I'm an apprentice die maker working on body dies, and that's something we do to check for continuity on curves and shapes after grinding/welding. For shorter spans we use banding straps or flat mahogany strips and brush on something like Dykem's "hi-spot blue" which shows every imperfection. It's quicker than applying layout blue and scratching it to check for high spots, which is also a viable option.
Thanks for the videos, I've enjoyed seeing your processes. It's inspiring to see you build this stuff from scratch, keep up the good work.
Great to see you back on the Zephyr. I'm a former bodyman from the 60s and appreciate your hard work.
Always nice watching a Sculptor work ... (like watching an amazing street performer)
Teaching the details you look for in your work/passion are invaluable.
Nice seeing how you have the time and inclination to test two different methods also on one already 'almost' perfect piece .. Perfection can be a curse 😄
Do I think there is a better way???? Karl, you're very kind. This is simply awesome. Every time I watch one of your great videos I feel blessed you are so willing to share. Thank you so much.
awesome dogs, Karl, and always enjoy watching you build and fabricate. Glad to see you getting back on the Zephyr! It's really shaping up. Glad it's starting to flow again for you on it!
You showed just how much work must be done to create a custom car. You do have perseverance.
First time tuning into this Zephyr build and I’ll be here until the end!! 👏👏👏
A true craftsman if i've ever seen one. excellent work. thanks for the inspiration!
Hey Karl, great video and thanks for bringing us along. One of the most precise ways you can cut that hole is with a boring tool in the tool post. You actually seem to have one in your tool post that you are using for facing and contouring. If you set that boring tool up on the center line you can cut a very precise hole. It’s called a boring operation. You remove material from one side of the cut and it’s super easy to get a round hole. Just plunge a hole with a twist drill large enough to get the boring tool in and then open it up to size.
Karl, the best way to do large holes is to drill to one size smaller than you want and then use a boring small bar to finish them to size. That way you are not at the mercy of the drill bit to get a straight concentric hole.
PS:
me thinks by the look of it that maybe you should take a day and give your lathe a little TLC, a little cleaning, and maybe even painting, never hurt anything. 😁
That first piece would have been welded on 99% of the time. Your desire to make it as good as possible is what makes your channel awesome. I found your channel through a friend sent me a link to one of the episodes putting hydraulics in the caddy (I've got a 61 Impala with front hydro that I'm getting ready to do 4 wheel on) and been hooked from the first video. Keep the killer work coming man!!
I'm blown away by the lathe work. You're a -wizard- robot, Harry!
Glad to see a video on the Zephyr. Been awhile. Thanks Karl. Your a perfectionist. Brent started a project that you might go over a day or two and help him. Thank you for sharing!
I'm so glad you are back on the Zephyr Karl. One of the most beautiful cars ever made in my opinion. Your fabrication skills, good eye for design and talent made that body line look easy. She is starting to flow nicely to the back to one of the most beautiful car rear ends in automotive history. I'm looking forward to seeing this one finished. Thanks for all the efforts Karl. Great work!
Thanks so much man! Cheers
Love the cab over a ton but I'm really glad you're back on this Zephyr project. Actually I learn a lot from all of your videos, however, this body style is so desirable. I think we should call you Professor Kustom because of your teaching abilities. Oh and again I( love the editing and music, perfect.
Karl, I’m sure you are aware of them, but just in case you are not, annular cutters drill a more precise hole than standard twist drills. I use them in my mag drill and the hole quality is superb. I know you can get adapters for them to fit a Morse taper. So you could use them in your mill or even possibly your lathe.
Or drill the hole undersize and use a boring bar ;p
@@grubsrust299 I was just about to say this.
Yeah, I think I could’ve used a boring bar to make them fit super super mint
A drill will never give you an accurate hole. Next time drill undersized and use the boring bar you have to finish to size. If you don’t have a way to measure inside dia make up a test bar to the size of the bead roller and use to test fit.
Karl, I appreciate the fabrication videos, and glad your back on the Lincoln. Don't forget the Taco offer...
Atta boy Karl…..you made a perfect panel. It’s already good enough for paint without any body filler👍
Thank you for sharing your knowledge and especially for talking through your thought process.
This is why you’re the best brother! Most people would have just used a little bit of body filler to smooth out those minor bumps but your relentless pursuit of perfect metal just wouldn’t allow it 👍 great vid, i with I had your lathe! Tell Brenda I says happy 2023! 😍
It is amazing to how much one little piece a few feet long can take to form. And what does he say you're not done with it yet you have to weld it in. Of course anytime you weld something there's still some forming. Fantastic video able to learn some things without feeling like I'm sitting in a classroom. Interesting and entertaining. Thanks for taking time to make the episode
The creativity of using tools like the english wheel to get that last little curve at the end is awesome!
Absolutely brilliant Carl looks spot on to me
So glad I found your page. The detail you show is amazing thank you
Got the line spot on pal ! great to see the process of how you got there👍
@MakeItKustom- hey Karl love the content
First I salute you for being able to make dies that match an existing contour. Nice coordinated hand-wheel operations to get the shapes you need. I was also impressed that you bought two blanks. I would have bought a foot of stock, and probably needed most of it :) But I do mostly CNC now, so it comes out perfect quicker, and I can make 1 or 1000 with no sweat.
However, for concentricity and precision, drill undersize and use a boring bar to get the exact size you want. Using reamers and using boring bars are precision operations, while drilling even with a new drill on a mill or lathe is not.
I know it is an old lathe, but please cover the ways when using sanding or grinding tools. That dust will eat the ways up on the lathe in a short time.
Wow, someone that knows how to read vernier calipers. I continue to be impressed.
SCAM?
@@dennisschickling2249 I reported it as soon as it shows up. It seems these days 1 in 5 of my posts on youtube get this crap.
Very interesting video, shows how you have to really understand what the metal wants, to achieve a result.
I was repairing some 69 VW Squareback fenders and between you and Fitzee I was able to figure out how to do it. Just below the headlight buckets the metal was like swiss cheese. The fenders had 6 different radiuses and then there was the style lines on the fender, and a spot-weld flange for re-attaching the headlight bucket. I had tried to make the part in one-go, but it never turned out right. Then I saw how you were going to make the style line on the Zephyr and then weld the rest of the panel to that piece. So, that got my brain turning. Then I saw Fitzee's Cut-n-Butt repair video and that did it. I prepared the internal spot-weld flange by hammer forming, then cut it up into threes. Spot welded the pieces into place and then formed the radius it needed. I still need to practice more, but my fender dilemma is done thanks to you and Fitzee.
Your attention to detail is amazing. Great work.
Haven’t watched in a while , what great one to come back too ! Always inspirational 👍🏻
Thanks man!! Love what you do brother!
Thanks man I appreciate the extra support 👊
heck yeah, Karl, glad to see you getting fired up to get back at the Zephyr to tackle the body work!
One of my favorite videos you have done. I like that you try new techniques. Even though it didn’t work, I like that you showed the process of cutting the arch then trying to form it. It seemed like it made sense. Thank you.
Happy Karl, I wish you, your family and friends a prosperous, healthy and safe New Year. The Zephyr is a great start, happy to see you back on it. I think it will be a real gem when you are done and I love their shape. I love your creativity and skill set, which just keeps growing as you share that journey with us. Good on ya mate!
Brilliant work. As a machinist I sympathize with drill bits wandering a lot. To fix this we always drill undersize and follow up with an on-size reamer, it provides a cleaner and more precise finish 🤘
Exactly what I was thinking back when you did the other panel, and was not happy with the line. Good job!
Karl, you are my metalworking spirit animal.
Great attention to detail, as always. I noticed the Cadillac is not in the shop the last few video's, really enjoy watching the work on it.......
Jay the Florida pool pump motor repair guy. When Service Calls Longwood approved ! that was good info 2 see& know👨🔧looks cool, good job !! Make it Kustom
Karl you are a total BOSS ...super talented ..keep the videos coming...
You show great restraint and patience to go for the second iteration of the strip rather than settle for the first. that seemed to work okay but perhaps not good enough. Great work and presentation Karl!
I can't believe you just etch-a-sketched that contour on the lathe. Well done.
I just have one word for you…..Roadster. That car looks awesome without a lid. I’m just sayin’!!
Cabriolet.
Karl, I so admire your meticulous attention to detail. I myself get into a project with the best of intentions and then am like, "gotta get it done!", and detail kinda goes by the wayside. Wish I had your patience. Also, I will be paying close attention to your 3 window fabrication because I have a 5 window Plymouth Coupe that I plan to build into a three window, and want to finished it for Winfields next show. So thank you for the glimpse into your minds eye, and I'll be watching and learning as you go. "Hep"
Stellar work as always, thanks for taking us on the journey as you develop the strategies to complete your vision. Cheers!
Hey Carl, your apprentice and cameraman is doing a great job 👍 Also, You do amazing work Carl, plus, your humble, smart, and a really cool guy 😎 Your headed to legendary status like "Lead Slinger" from the 50's & 60's. He worked on builds the old school way with that fatty cigar in his mouth and did it through his 80's. You have the same cool build style as the Legendary Lead Slinger, so awesome Carl!!!
Ha ha, thanks Jason! Bill Hines is a legend
Karl glad to see you Back on the zephyr Coming along very Nice And that a Nice Tool bag
what I hate is your attention to detail, what I love is your attention to detail... I know :)
Good job. I watched Lazzy put 2 dies side bye side on the bottom shaft of his bead roller and it made a step notch and he used the notch as a fence on the die itself. That way you can bead roll long swipes and the roller die work as the fence. I hope that makes sense. That's how he showed me how to make model A rear corner panels. It works pretty good and I think he even sells some of his dies with a shoulders machined on the die so you don't have to stack dies side x side.
Finally!!! Been waiting for you to get back to this project
You should totally invite Fitzee to come work on the zephyr with you for a couple days! This is right up his alley, I’m sure he’s watching intently too!
You have some very nice tools, wish I had a lathe. Great attention to detail.
if you want to see if there's a flat spot in the new panel when you make the other panel flip it over and lay them alongside each other than you'll be able to see any flat spots easier. The lines are looking good Karl. Your getting there, keep it up.
Looking good, it will weld in and planish up nice, good move grafting it in above the fender.
Very good freehand die making , as a retired toolmaker I love to watch your skills!
Would like to see more on this build. You are doing a good job.Nice attention to detail.
Interesting piece to make, it looks good out here in monitor land and I am sure in the shop it does too. Thanks for the lesson. Everyone has a way to do things and it is always great to see a different way.
Karl, here's a way to ensure that future bead rolling dies have round holes in the center of the dies, but it may be more work & accuracy than needed depending on the use (other than bead dies): Start with a spotting drill or justcthe small tip of a center drill to keep your first drill close to true center. (Also remember that twist drills don't usually drill round holes.) Step up in drill sizes (like you do), but keep the hole undersized enough to be corrected with the largest boring bar that fits. The boring bar will correct a hole that's off-center to be back to truly on center. You can finish a bored hole with a reamer if you need a really good finish. I'm not a professional Machinist, but I believe that this is the proper procedure to ensure a hole is actually where you want it.
Another possible reason for the problems you discussed could be the accuracy of the two shafts on the bead roller where you attach your dies. If they aren't exactly the correct diameter, or if they are worn, that could be a source of what you see as oblong discrepancies in the parts that you bead roll.
I'm not trying to find faults with what you do - I'm just trying to offer possible ways to improve future parts made on your lathe & offer, from the peanut gallery, possible sources for the less than perfect to your eye parts that you see as being caused by oblong tooling.
I am always amazed at what you make in your workshop just by using your skills & tooling that you design & build in your own shop. Definite thumbs up!
Boy, I'm glad you're in charge of production. I would hardly have noticed the lumps, let alone put myself to the trouble of ironing them out. Might be the reason I haven't been able to flip the last four 1939 Lincoln Zephyr 3w Conversions I've done. Seriously though, your design decision-making process is so exacting that what comes out is always spot on. And I really like that you have Elio to sound off your ideas on - really brings us into the conversation too, I reckon.
I think the piece turned out great. I enjoyed watching the process of the whole thing
I've seen some guys run the sheet metal through a planasing hammer on the same area that you wish to bead roll first, must just thin the metal ever so slightly to help the bead rolling process. keep up the good work brother.
Happy new year karl . Great to see the zephyr back into the playlist , very gratifying to see a finished part that meets your exacting requirements. The attention to detail goes above and beyond what most would be happy with . Looking forward to seeing you welding those on and bringing the body further along towards completion . I'm surprised with the dies you didn't just pop them back in the lathe and use a boring bar and then add a new centre spacer . Thanks for bringing us along on the ride tho very good evening entertainment and just an amazing way to learn something .
With the very few patch panels I have made, I always found a better result when I made the part bigger than needed. Everything seems to flow better and line up easier. Good call on this one!
SCAM?
Love the Zephyr, good stuff, keep it going...
Great update. That Zephyr is going to be beautiful. Music nice-lots of reverb. Thanks.
YES! YES! YES! Another great video from Karl the Kustom Kreator. Love your work always Mate. I was so waiting for this post so much. Billy J...... Queensland, Australia. 🚑🚓
Nice job making those dies. More power to you.
another nice video, some nice freebies at the end. lovely.
I'm in the middle of my first attempt at major body sheet metal mods.
One thing I did, though, when I pieced in another panel was to radius the corners of the patch piece, rather than a sharp 90 degree angle at the splice point. I did a large radius at the corners.
I tell you Karl it all about patience and homework,great work too....🙂👍🙏
Killer job with the dies and panel! I was thinking earlier at today that when there will be the next Zephyr video? And here it is!
Keep up the good work!
i love your channel content i started watching you then brent on halfass kustoms and love his channel too. both excellent choices really great channels.
Thank you i learn so much from you both great teachers..Very Skilled and Creative
As usual great stuff here Karl ! Really enjoyed the collaboration with Half Ass !