Steel sheets, 20-gauge, at least 18"× 28" each ( 2)
Aluminum sheet, 12-gauge, at least 14"× 7¼"
Drill and drill bits:
Tape: double-sided and masking
Pop rivet gun
Tinsnips and scissors
Dremel tool with cutting wheels
Metal files and sandpaper
C-clamps and scrap wood blocks
Hammer and center punch
Fine-point permanent marker
136 Make: Volume
1" holes around the perimeter of body piece
A1/A2 as shown on the template (Figure A). For the
8 oval cutouts in E1, drill holes inside each, then
work the shapes out with a file.
If you like, you can prototype the project in
cardboard before going to metal. For more advice
on working with sheet metal, see my Retro Racer
project (MAKE Volume 11, page 97 ) and Mister
Jalopy’s “Q&D: Holes, Rivets, and Bent Metal”
(Volume 05, page 110).
2. Weatherize the trunk lip.
Cut the inner tube lengthwise, wash it thoroughly
with soap and water, and let it dry overnight.
Lay the trunk lip piece D1 on wax paper, then
coat it with E-6000 glue. Cover it fully with flat
pieces of inner tube, then more wax paper. Clamp
it all flat using C-clamps and scrap plywood.
Let the glue dry for 3 days or more, then remove
the clamps and wood, and peel off the wax paper.
Trim any excess rubber around the edges of the
metal with an X-Acto knife.
3. Bend the sheet metal.
Using the sheet metal brake, bend down the 2
middle lines of piece A1/A2 at 42° (Figure B,
opposite), then bend the bottom tabs inward
at 90°. Similarly bend B1, C1/C2, D1, and E1 along
the lines indicated on the templates.
NOTE: Front cap B1 and end cap C1/C2 look
very similar; don’t mix them up.
4. Drill matching holes.
Temporarily assemble end caps B1 and C1/C2 to
the body A1/A2, clamping them together at the
bottom. Fit them at the top and re-drill through one
1" hole on each bend plane in A1/A2. Pop-rivet
through these holes to hold the pieces in place
temporarily, then drill through all the remaining
holes (Figure C).
Drill out the pop-rivets using the same
pull everything apart, and file down any burrs.
5. Rivet and seal the trunk.
Now that everything lines up, put it back together
again. Glob the Dynatron putty on the tabs of B1
and C1/C2 and rivet the pieces to A1/A2 through
all the holes (Figure D). Wipe the excess putty with
a rag and let it dry.