7-DVD Set: Parts Fabrication Fundamentals
Metal and Parts Fabrication is the foundation of the classic car restoration process. In this huge comprehensive 7-DVD set, you’ll see first-hand the tools and processes to repair or replace many of the components on your car.
Mark Simpson and Gary Simpson team up to bring you a wide range of metal fabrication tools, and instruction on how to use them, from English Wheels to Bead Rollers to MIG & TIG welding. With this set, you’ll learn how to repair, form, modify and weld many parts and panels.
Also, Bob LaRosa joins the team to demonstrate the correct way to make fiberglass molds and how to use them to create your own custom carbon fiber parts. Mark also demonstrates one of the oldest forms of metal shaping, known as Hammer Forming; a great process to build your own custom parts using basic shop tools. The team also shares many of their favorite tips and techniques sure to make any classic car restoration easier, better and faster.
Enjoy our largest and most comprehensive parts fabrication set, with 8 hours, 15 minutes of detailed how-to instruction.
See below for details on each of the videos you’ll receive:
Metal Fabrication Tips & Tools – 60 minutes
Classic car restoration often involves some level of metal fabrication. Even if patch or replacement panels are available for your car, they’ll likely need some fabrication to make them fit as they should. Mark Simpson explains the use and function of some of his favorite metal cutting and fabrication tools.
We’ll take a close look at these great tools and how to use them:
Cleco panel holders: These blind clamping tools make it easy to hold panels tightly together until they can be welded.
Beadroller: When duplicating trunk floors or body panels, the bead roller serves to duplicate factory ribs and flanges while adding strength to metal panels.
English Wheel: Almost every steel panel on the outside of a classic car has a crown in it. This tool is perfect for duplicating panel crowns or even straightening badly dented panels.
Shrinker/Stretcher: Making pre-made patch panels fit properly can be a challenge, but here’s a tool that can make fast work of achieving a perfect fit, and a valuable tool when fabricating panels from scratch.
Sheetmetal Brake: If you’re fabricating a patch panel or a new battery box, a sheetmetal brake is a must-have tool in most restoration shops.
Plasma Cutter: In many shops this tool has replaced the Oxy/Acetylene torch for cutting metal, as its accuracy, control and versatility make it a highly useful tool.
We’ll also look at a great tip to quickly and cleanly pick up metal shavings without getting stuck.
Restoration Tools, Tips & Techniques – 58 minutes
If you’ve spent any time in the shop working on your classic car, you’re fully aware of the importance of having the right tool for the right job. But we all have to start somewhere, and for many of us our arsenal of shop tools was not a single purchase but rather an accumulation of a lifetime.
But what do you need to start restoring your classic car? Mark Simpson takes an inside look at the tools most car guys should consider to make car restoration easier, faster and safer. We’ll take an inside look at everything from screwdrivers to floor jacks and everything in-between.
Also included in this DVD, Simpson shares some of his favorite car restoration tips and techniques on everything from: Keeping spray nozzles clean; no-scratch fender covers; cleaning white-wall tires; cleaning/storing respirators; masking tape rejuvenation; and many more. These tips are proven time savers, certain to make your time in the shop more enjoyable.
We’ll take you through the process of at-home Powder Coating, from preparation to finished parts. Powder coating allows you to put a nearly bullet proof finish on car parts that is guaranteed to outlast most painting or plating techniques.
Plastic gauge and instrument lenses can become scratched and fogged over time, and for many enthusiasts reproduction lenses simply are not available. We’ll take you step-by-step through the process of restoring these plastic lenses to “like new” condition.
MIG Welding and Oxy/Acetylene Cutting – 61 minutes
MIG welding, or often referred to as “Wire-feed welding,” has become the standard for most home enthusiasts. With a moderate amount of practice almost any car enthusiast can create quality MIG welds.
But there are a few things you should consider to ensure your welds look good and have the strength you need. Gary Simpson takes you through the process including: Safety, Equipment, Setup and Adjustments.
Simpson then demonstrates the processes to prepare the metal for welding and the importance of removing mill scale before welding. Knowing how to weld different joint types is key to ensuring success when MIG welding. Gary explores many common MIG welding joints and thicknesses of material and demonstrates how to properly weld each of them.
Also, when doing a complete car restoration, you’re bound to find a few extra holes that have been drilled into your car over the years. We’ll demonstrate a couple different techniques to properly MIG plug weld to fill holes.
Once the Oxy Acetylene torch was the tool every car guy grabbed first and was a must-have for any die-hard car enthusiast. Advancements in MIG and TIG welders, plasma cutters and the like have diminished the need of this great shop tool. But the old gas axe still has its place in any well-equipped shop – and knowing how to use it safely and properly is key to your success. Mark Simpson demonstrates setup and safety as well as how to properly use an Oxy Acetylene cutting torch to cut steel plating.
Cutting tubing is a mainstay of metal fabrication. Fish mouthing is a process of creating a weldable joint when joining two pieces of round tubing, while jigs are available to simplify the process. Gary Simpson demonstrates how to create quality fish mouth tube joints using simple hand-tools.
Creating square cuts on round tubing with hand tools can be challenging too. Simpson demonstrates the process of laying out straight and square lines on round tubing and how to cut them.
Carbon Fiber Mold Making – 83 minutes
Knowing how to make custom parts is key to creating one-off custom cars and trucks, or simply to fabricate parts that are not available for your classic car. In this video, Bob LaRosa introduces you to the products used when fabricating carbon fiber and fiberglass parts. He also shares his safety insights to ensure your project is completed without any surprises.
LaRosa then takes you step-by-step through the process of creating molds, using mold release agents, layering substrates, creating practice forms, and much more! If you’ve ever considered making you own fiberglass or carbon fiber parts this video is a “must-have” to help ensure your success.
Hammer Forming Fundamentals – 65 minutes
Hammer forming sheet metal is one of the oldest forms of metal fabrication known; Mark Simpson introduces you to the process and the materials used in forming projects. Using basic hammer forming techniques, Simpson transforms two flat pieces of aluminum into a custom air cleaner. Using this process virtually any sheet metal part can be recreated from patch panels to custom center consoles; there simply are no limits.
The first step is planning out what forms will be needed to get the job done. Simpson takes you through the process of designing patterns and preparing to cut out the form and clamp. Building a “Form & Clamp” for hammer forming requires only simple hand tools. Mark shows you the process of cutting and sanding to achieve a high quality form.
TIG Weld / Media Blasting / Install Lowering Blocks – 75 minutes
TIG (Tungsten Inert Gas) welding, was known for years by many enthusiasts simply as heliarc welding; a process that often involved very expensive equipment and gases. The cost of equipment has come down dramatically over the years and is now within reach for most auto restoration hobbyists. Getting started TIG welding, requires getting the right setup. Professional hot rod fabricator and welder, Gary Simpson, explains what you’ll need to get your equipment setup, welder settings and work area to ensure high quality welding results.
Like many welding processes, it takes some time, training and practice to perfect, however the advantages TIG offers outweigh the investment you’ll make. Splatter free welds, precise control of the weld area, and the ability to quickly change between welding aluminum, steel and stainless steel, are just some of the advantages you’ll discover.
Mark Simpson demonstrates how adding and properly maintaining an at-home media blasting cabinet can dramatically improve the quality of your restorations. He shows exactly what steps you need to know to: maintain the consumable parts, selecting blasting media, safety considerations, preparing parts for blasting and how to protect the parts you don’t want blasted.
A popular conversion to give cars a more modern stance is the addition of lowering blocks. Mark will take you through the process of adding lowering blocks and important considerations that should be made when deciding exactly how much to lower a car.
Carbon Fiber Parts – 93 minutes
If you’re serious about creating custom cars and parts, this video is for you! Bob LaRosa takes you through the process of selecting the right products, cutting the carbon fiber and laying up carbon fiber parts. When done right, carbon fiber parts are stronger than steel at a fraction of the weight; here is your opportunity to gain LaRosa’s personal tips tricks and insights.