How to Fabricate Complex Repair Panels With a Pullmax & Hand Tools
Elliot Armstrong-Watkins
20,612 views
In this video, I show you how to fabricate complex classic car repair panels from scratch using a Pullmax machine and traditional hand tools.
We start at the back of the workshop, cutting the original glued glass out of a classic body before making the executive decision to slice away a completely rotten outer panel. Once the metal is gone, we uncover a major structural disaster: the bottom two inches of the inner frame are completely rotten, and the hinge mounts are severely rusted.
To fix this properly, we clean the reinforcement plates with heavy-duty acid and use custom-made steel Pullmax dies to rapidly hammer and shape a flawless, stepped factory-style repair section completely from flat sheet steel.
Whether you are restoring a vintage car or learning advanced sheet metal shaping, this step-by-step fabrication breakdown shows you how to tackle deep rust the right way.
Hit SUBSCRIBE to join our weekly solo factory journey as we race the clock to get this build ready for Capriciation 2027 at Bathurst!
Chapters:
0:58 - Cutting Glued Classic Car Glass
01:37 - Why Slicing Off a Rotten Panel is 4x Quicker
06:51 - Pullmax Masterclass: Stamping Stepped Profiles from Scratch
11:23 Old school Oxy Acetylene Gas welding the new Panel Section
14:36 - Chemical rust treatment done the right way
16:22 - Hand forming a complex repair section by hand
#MetalShaping #ClassicCarRestoration #Pullmax #HandTools #OxyAcetylene #Welding #Handmade #AutomotiveFabrication #Capri28i
20 Comments
Watching from Peterborough, UK.
I've had 5 Essex V6 Capri's. They were quite popular around here so I shared your channel on FB
How to Fabricate Complex Repair Panels With a Pullmax & Hand Tools
Elliot Armstrong-Watkins
20,612 views
In this video, I show you how to fabricate complex classic car repair panels from scratch using a Pullmax machine and traditional hand tools.
We start at the back of the workshop, cutting the original glued glass out of a classic body before making the executive decision to slice away a completely rotten outer panel. Once the metal is gone, we uncover a major structural disaster: the bottom two inches of the inner frame are completely rotten, and the hinge mounts are severely rusted.
To fix this properly, we clean the reinforcement plates with heavy-duty acid and use custom-made steel Pullmax dies to rapidly hammer and shape a flawless, stepped factory-style repair section completely from flat sheet steel.
Whether you are restoring a vintage car or learning advanced sheet metal shaping, this step-by-step fabrication breakdown shows you how to tackle deep rust the right way.
Hit SUBSCRIBE to join our weekly solo factory journey as we race the clock to get this build ready for Capriciation 2027 at Bathurst!
Chapters:
0:58 - Cutting Glued Classic Car Glass
01:37 - Why Slicing Off a Rotten Panel is 4x Quicker
06:51 - Pullmax Masterclass: Stamping Stepped Profiles from Scratch
11:23 Old school Oxy Acetylene Gas welding the new Panel Section
14:36 - Chemical rust treatment done the right way
16:22 - Hand forming a complex repair section by hand
#MetalShaping #ClassicCarRestoration #Pullmax #HandTools #OxyAcetylene #Welding #Handmade #AutomotiveFabrication #Capri28i