In this post, we remake an original panel that is rotted out and the only replacement available is in fiber glass, which isn’t going to work for the customer, or fit with this type of build. The alternative is to make one from scratch (flat sheet metal) using the rotted out panel as a pattern.
Check out the photos below, as we make the panel from scratch with the aid of the sand bag, plannishing hammer, and English wheel for total shape definition.
Chevy truck lower grille shell before restoration
Original rotted panel is now serving us as a pattern.
Fabricating a new grille shell panel
Blocking out with a wooden mallet and a sandbag.
Plannishing hammer in use.
Pattern progress check.
Smoothing up and defining with the English bench wheel.