Pre 1958 - Fabrication of end cap panels

[vintageair]

Hello,

I'm looking for someone that can supply the tooling ( up to 6ft ) or sheet with the correct edge profile for 13 panel trailers.

Needs to be a 99.7% match for the original.

Does anyone recall any previous postings on this or has anyone had success in producing an exact replica panel.

Thanks,

Sam.

[truckasaurus]

I don't have that style end cap but in your photo it just looks like a bead rolled edge, you can get or make a hand sized tool for that.

[Melody Ranch]

send me a PM...how many do you want?

[vintageair]

Originally Posted by truckasaurus

I don't have that style end cap but in your photo it just looks like a bead rolled edge, you can get or make a hand sized tool for that.

I'm thinking this has been covered many times already on the forums, but i just could not find the right thread.

It's slightly more than a rolled edge. The edge profile has been formed with tooling that leaves not only a rolled edge but also a line pressed into the side of the roll which is away from the edge of the material.

It appears a simple tooling, but would cost me a good bit to get made up to replicate the original.

I'm looking for an exact/99.7% match to the original.

Many thanks,

Sam.

[truckasaurus]

I'll take a snap of the tools I have at the shop for this and see if it's the same thing.

[BradS]

I cut out my blanks and took them to a local sheet metal shop, I took along an old segment and said please match. Im happy with the way they turned out

[vintageair]

Originally Posted by BradS

I cut out my blanks and took them to a local sheet metal shop, I took along an old segment and said please match. Im happy with the way they turned out

Brad,

I had a look at your work, very nice. That was pretty bad damage you fixed.
Would you have a close up of the bead your local sheet metal shop produced?

I wonder how Airstream did it back in the fifties, would they have rolled the bead in or pressed them?

These seems good, if they come with the right dies/mandrels -

Eastwood Bead Roller and Flanger Kit - YouTube

[BradS]

The bottom bead is the factory and the next one up is new

[vintageair]

Originally Posted by BradS

The bottom bead is the factory and the next one up is new

Brad,

That looks very close.

Just one little thing, looking at the bead, there appears to be an extra profile line on the edge side of bead, it that correct?

I wondered if anyone has managed to get a the exact bead replicated and if so, what roller/die set/mandrel setup would they recommend using for a small workshop. Something with the flanging capabilities would be a bonus.

Many thanks,

Sam.

[Frank's Trailer Works]

The bead you seek is not a uniform bead. It changes slightly year to year and dramatically from California to Ohio. To get a 99.7% perfect match will require matching the year and factory.

PS, 99.7% perfect is going to be nearly impossible to achieve. We are humans and we are fraught with error. Aluminum can only be 99.7% pure after extensive purifying. Bleach can only kill 99.8% of what it contacts. The birth control pill is only 99.6% effective allowing for 4 out of a thousand pregnancies.
It is very admirable to hold others to such standards however.

[vintageair]

Originally Posted by 62overlander

The bead you seek is not a uniform bead. It changes slightly year to year and dramatically from California to Ohio. To get a 99.7% perfect match will require matching the year and factory.

PS, 99.7% perfect is going to be nearly impossible to achieve. We are humans and we are fraught with error. Aluminum can only be 99.7% pure after extensive purifying. Bleach can only kill 99.8% of what it contacts. The birth control pill is only 99.6% effective allowing for 4 out of a thousand pregnancies.
It is very admirable to hold others to such standards however.

Thank you Frank,

I was looking closer today at the profiles in my barn and picked up on what you mentioned between years and factories. There are indeed many different types of beads so I will start experimenting.

Many thanks all.

Sam.

[Frank's Trailer Works]

I have searched for the thread, but the tool is two bearing mounted to handle. The angle you hold it and the pressure you exert will affect that crease you note at the edge.

[Aerowood]

These pics

[truckasaurus]

Not sure if this'll help at all but this is one of ours at the shop. The lower cylinder is compressible material. The palm sized version is handy too if you are working solo.

[vintageair]

Originally Posted by Aerowood

These pics

Aerowood,

Many thanks for pictures.

Have seen these tools posted before on the airforums, which prompted me to I get a set like this -
Buy Aircraft Tool Supply FT100 Hole Flanging Tool- Sky Geek, Skygeek Owner Shop, Shop Supplies, Tools, Sheet Metal Working Hand Tools,

They are great for small one off pieces, I have used them for eyelids, but like Frank mentioned it's difficult to get a uniform finish.

Sam.

[BradS]

When I was replacing segments on my trailer I looked at a lot of ways and bought a few tools to try. In the end I needed close to 90 lineal feet of this profile produced. I chose to have it done and It cost me about $1.00 per foot.

I have also noticed that the bead changes from factory to factory and year to year. I would guess the profile was a little unique to every person that made it. If your replacing segments I would consider taking the old one and the new blank to a sheet metal shop. Explain your dream, tell them about your trailer and have him do it