Sheetmetal panels are used extensively in classic truck projects, often for interior and underhood panels. While fabricating panels can be as simple as cutting and fitting, there are some simple tools that can add detail to create more visual impact, and each of these detailing steps add strength to the panel as well.
Just a few details can transform a plain piece of metal into something quite striking.
We will look at the Dimple Dies made by Hammerfab, which form a strong, good-looking detail around the heads of any fasteners. The most common styles are Flat Recess, Flush Recess, and the ever-popular Crater Maker. All of these dies are precision machined from heat-treated 4140 (chromoly) steel and are very durable. You have seen these used on many trucks featured in this magazine by both professional shops and homebuilders.
These are the Flat Recess dimple dies designed to make an indentation in sheetmetal panels to slightly recess a screw head or washer. They are available in sizes for #10 to 1/2-inch screws.
The dies come as a two-part set, with a male and female die. There is a center screw that aligns the dies, and with thin metal panels in the smaller sizes the screw can often form the needed detail. For larger size screws and thicker metal, a vise or press is recommended to push the dies together. The photos show how easy it is to use these dies and the professional-looking details they form.
The first step is to drill or punch a hole in the metal the size of the screw. We’re punching a hole for a ¼-inch screw here.
There are some other dies available, for uses like flush-setting rivet nuts, Dzus buttons, and some other specialty applications. Using these simple tools can really step up the quality of your work.
On thin metals, and with the smaller-size dies, you can use a screw to pull the dies together. It’s a good idea to use some lubricant on the threads.
Round Over dies work on a bead rolling machine, and they put a curl on the edge of a sheetmetal panel. This is very simple operation, but it can offer a striking amount of style and strength. The dies have a guide built into the lower die, and as long as you keep the edge of the metal in contact with the guide, the curl will be perfectly formed. These dies are sold by Trick Tools and are available in four sizes. We are demonstrating the smallest size here, which is the 5/16-inch radius.
For thicker metals, and for the larger-size screws, it’s best to use a vise or a press to set the dies.
The Punch & Flare dies, made by Mittler Bros, make holes with radiused (or “belled”) edges. The round dies come in sizes from ½ to 3 inches; triangular and oval dies are available, too. Dies like these are used extensively in aircraft construction because they can both reduce weight and strengthen the panels they are placed in. Weight is not commonly an issue with truck builds but strengthening sheetmetal panels is often beneficial, and they have a unique look that most people like. These are often called “speed holes” by those in the trade.
Each of the dies will form a crisp, clean indentation in sheetmetal panels.
The photos show many applications for these simple tools, and we’re sure you can envision many ways they can step up your metal-fabrication game!
With screws and washers in place, the slight indentation provides a nice accent for each fastener.These are the Flush Recess dimple dies for use with flathead screws. They are made for screws from #10 to 3/8 inch.The dies can be set with either a screw, vise, or press depending on the size of the fastener and the thickness of the metal.The flathead screws fit completely flush This provides a clean look and can be beneficial in applications with limited clearance.The most popular dies are the Crater Makers, which form an attractive raised feature around the head of the fastener. They come in sizes for screws from #10 to ½ inch.These dies require higher force to set, so a vise of press is recommended in most cases.The raised detail around the fastener head adds strength and a nice visual detail.Another tool that can add strength and character to the edges of sheetmetal panels are Round Over dies, used with a bead roller. They come in four sizes; we’re using the 5/16 size for this demonstration.The forming action of the dies will be uniform as long as the edge of the metal is kept tightly against the guide built into the lower die.You need to think about the sequence of operations when using these tools. If the dimple dies had been used first, the Round Over dies would collide with the edges.Punch & Flare dies are a terrific way to both lighten and stiffen sheetmetal panels, plus they add a lot of visual character. They come in sizes from ½ to 3 inches.The dies are very efficient because they first punch the hole, and then flare the edges in the same setup. The smaller dies can be used by tightening the die halves together with the center bolt, but a press is preferred for the larger sizes.The smaller sizes can be tightened with the center bolt but a press is recommended for the larger sizes.The broad range of sizes allows you to place flared holes in nearly any panel you can imagine.While most often used on flat panels, the dies can work on curved panels, too.Parts of virtually any size and shape can be improved with these detailing toolsThese details can help you add strength and style to your sheetmetal parts.With some creativity, you can use the Punch & Flare dies for other garage or mancave uses, like this versatile rolling stool and the portable file holder.
