The process that I use to design and build a gas tank from the SolidWorks design to metal is this:
1. Create a Buck
A buck is a 1:1 scale model of the part that is to be shaped in metal. A buck can be made out of many types of materials, the most common being wood or foam. Foam bucks are carved, so they offer true surface information for the part being metalshaped. A wood buck on the other hand is typically constructed so that it forms the internal skeleton of the structure (ribs and cross members). The bucks for both my gas tank and seat cowl are the wood type.
2. Flexible Pattern
A flexible pattern is like a skin that is taken from the bucks. Its purpose is to provide surface information that is very useful in the metalshaping process. A flexible pattern is created by first applying a layer of low adhesive masking tape to the buck, and then applying a layer or two of fibreglass packing tape.
3. Panel Beating
Using the flexible pattern and buck created in the first two steps, a portion of sheetmetal is cut and stretched and shrunk with a small assortment of tools (hammers, sandbag, stump) and an English Wheel to achieve the desired shape. The key is to continually check against the flexible pattern and buck to ensure proper fit.
My progress to date on the gas tank has been pretty good. Both halves of the tank are approximately 85% of the needed shape, with a bit more needed before I can weld them together. After that I will create the knee cutouts, and then create the tank tunnel and bottom.
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