View Full Version : Sheet metal advice

07-19-2011, 01:37 PM
So I want to turn a set of doors I have on hand into the ones pictured below. The thing that is tripping me up is keeping the detail of the upper edge of the door. Most people just chop the top off with the profile they want and cap it with flat or round steel.

I am thinking of removing the top 2" or so of steel where the door meets the glass and keep that "bevel" detail. Then pie cut it to make my two bends at the front and rear of the door. Then I should need is to break a piece of steel to create a filler panel to connect the two pieces... does that make sense? See pic below... the red is what I will keep and pie cut, and the blue section is what I would fab from scratch.

Is there an easier way to keep that detail? I have thought about cutting a piece of .120" sheet to create the step down as well... might be easier to accomplish the right look, but it may actually create more work to get it just right.

What say you?

07-19-2011, 01:45 PM
Shape a block of wood to the profile you are interested in. Then hammer the sheet over the block to get the shape you want.

It will be a pain to cut/splice the sections from around the top of the door, but if you are just planning on using the straight sections, and making the curved section using the wood block then it's pretty doable.


07-19-2011, 02:08 PM
OR.... use a dimple die and roll the edge you want. but you're most likely looking at stretching/shrinking those complex curves.

07-19-2011, 02:31 PM
I'd cut the top of your door off about 2-3" and then make cuts about 80% through on the out side radius and shape it into the shape you like. Then cut small filler pieces of flat sheet to fill the gaps from bending and slowlly piece it back. It dosent have to be 100% with the steel. Because that type of contoure will be finshed with bondo. Just make a good near close base for the filler.

Or just trad for half doors

07-20-2011, 11:50 AM
Huh, never considered a wooden form to bend the steel on it. I guess its is time to start reading up a bit. Thanks guys.

07-20-2011, 01:10 PM
That's a really cool door... so are there holes in the top so would you be able to stick the soft top window into the top of it?

07-22-2011, 09:30 AM
That's a really cool door... so are there holes in the top so would you be able to stick the soft top window into the top of it?

No plans for a soft top as of yet. Though I have seen that done before and it looks cool. I am thinking of making a deep pocket on the inside once the window is removed from the inside.