Getting a handle on it

Once the buck is assembled paper patterns can be pulled from it to assist in cutting out and shaping the aluminum skin.

The parts cut, the first one formed as far as the half hard state will allow, the second partially finished.

Here I have cut out two pieces of Aluminum and started initial forming of the part after cutting it out.  The material comes in a half hard state so it can still be moved some but not a lot.

This is the first serious attempt to fit the part on the buck.

Following the initial forming phase, the part is annealed to soften it for further forming.

Once the part has been annealed, it forms a lot easier. Here I have made major progress towards shaping the metal skin to match the buck. As I  continue with the forming it is important to check the fit occasionally to make sure that I haven’t overworked areas.

The piece after one round of forming following the first anneal is fit against the buck to check alignment.

This is a section that has been annealed but not worked yet. With the part clamped to the buck the rest of it fits fairly closely so the big bulge here needs to be shrunk in to make the part fit.  The Buck measures 35″ and the edge of the bulge on the part measures 37″ .  Much of that can be removed in this pass of forming.

Here is the top left side of the handle in a near fit with a couple new areas marked for additional work. . . The big bulge shown in the previous photo is gone.