Homemade Tools, Powerhouse Cover Form

Tom Wesenberg

Tom Wesenberg

Well-known member
I finally finished making a tool I've needed for a long time. I'm no bodyman, and dents in the rear cover of powerhouse generators have been a problem. The owners put some dents in, then the post office often adds a few more dents. I've been needing a good form to use to help remove the dents. I couldn't find a block of steel 6" by 1 1/2", so I had to buy 3 steel plates 1/2" thick and weld them together, then buy some radius gauges to help me turn the correct shape. This took many hours to make and if I had it to do over I think I would have made two shapes, one for each step of the cover. Anyway, it's finally done and has worked well for the cover I'm working on now. It should save a lot of time on future covers dent removal.:)
 

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Pretty slick, nice idea. I poked at one for hub caps, and just could not get it right. Seeing yours make me want to try again.
 
crumbaa said:
Pretty slick, nice idea. I poked at one for hub caps, and just could not get it right. Seeing yours make me want to try again.
Click to expand...

Thanks guys. At first I was wondering how it would work to wax a good straight cover and pour cement into it and use that as a form?:confused: It seems like it might work, but I finally decided to go for the sure thing.
I never was a good gambler.:D
 
Nice little jig!

I have a secondary question, if you don't mind...

How do you deal with all that rust rash? I've been trying to develop a technique. All I've come up with is body filler. I get a tiny dab of red bondo on my index finger and press it into the rash. Let it dry, and then sand 99% off. All that's left is what fills the rash. It looks like bare metal with little red dots. Then I prime, and repeat until smooth. It usually takes 4 - 5 sessions with increasingly fine sandpaper to get it perfect. Then finally paint.

Is there a better way that doesn't involve body filler? (Sorry if this is not the primary point of this thread.)
 
Ray, I do the same. Years ago, if it wasn't too many pits, I would try solder, but that was very time consuming and didn't work as well as the method you just described.
 
Tom,
Why don't you bring the tool to the clinic Thursday for show and tell (if we aren't snowed out again)?
Rusty Nelson
 
Nice work Thomas, you have the patience and good ol' American know-how to get the job done correctly!!
 
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