MAKING HEADLAMP MOUNTINGS
Using a former
One method of forming a headlight mount is to use a steel or wooden former of the appropriate height and diameter to gradually pummel the steel into shape. The top of the wing can also be accommodated if one sector is left without a return.
Stretch outer flange
The nacelle needs to have a base with a larger diameter than the headlamp-mounting face, so it needs stretching. This is going to start looking ugly – but don’t worry. Coax the steel down as you stretch. Even if you do this, it will distort the other plane.
Finish with a hammer
Use a crowned hammer on a stump to stretch and shape the sides of the nacelle. Finish by stretching it over a suitable stake or dolly using a planishing hammer. Use lots of light blows to smooth it, working from the flange outwards.
Simple nacelle
A simple headlamp nacelle has a fairly cylindrical appearance. This can be made by folding a flange with a suitable radius, then shrinking the inner flange until the correct curvature is achieved. Correct concavity in the sides with a hammer/dolly.
Shrink inner flange
After putting in some stretch, the ‘L’ shape is going to look like scrap metal, but bear with it. Put the other side of the flange in the shrinker and it’ll start to pull round and straighten out in the other plane. Use light strokes at full depth.
Add detail
The Vanguard has a swage around the headlamp mounting face. This can be hammered into place using a shaped drift or using a swager with appropriate dies. The swage will wrinkle if you do this before shrinking – so shrink before adding details.
Making shaped nacelles
The sides of our nacelle aren’t parallel, but are flared outwards. Start by bending a flange with a radius that replicates the one required. Don’t bend the flange angle to 90°. Instead, bend it to match the start of the flare, as seen here.
Weld and finish
We’ve made our nacelle in three sections that fitted in our swager. You might get away with two – or even one. Trim the ends and weld them together (we’ve fusion-welded ours using the TIG process). Planish the shape before trimming off excess.