Here's some photo's of how I've spent the last day or so out in the shop. The panel had to be hand formed due to lack of availability. The rockers on a 122 are 18 gauge (about twice as thick as the sheet metal they sell at Crappy Tire - which is how I end up with forearms like Popeye...well my right forearm and shoulder are in pretty good shape).

Start by creating a positive form out of wood that perfectly fits the test panel (from Olof)...in this case a regular old 2X4 was used, then sandwich the metal between the form and another length of wood. Clamp it very tight with lots of clamps and then proceed with beating the hell out of the metal - only kidding . I use a urethane hammer for shrinking and a metal hammer for stretching (you have to figure out where things get shrunk or stretched). This takes lots of practice to get the hang of it, so to some it is voodoo, it's not - but it isn't easy either.



After several hours of massaging the metal you end up with this...a complete panel for about $5. Factory replacement is on the right - mine is on the left. If you look really closely, you can see the grain of the wood in the hand-formed part.




Here's an overview.




Time for a well-earned beer.

Uhh...I'll have a case for you when you bring that puppy up...

That looks awesome!

I hereby dub thee "Voodoo Car Dawkta"

nicely done

Vedy niiiice. Did you use the big shrinking wheel on the polisher too? That's really round.

I see the factory panel has an extra little lip at the bottom....you leaving that bit out? Not necessary?

No shrinking wheel on this one yet - probably when I have to address warped weld areas. I didn't form that extra lip as the original panel is a cover sill that goes over the inner rocker arrangement (total overkill at 18 ga for a cover) so there is another part that forms the bottom of the rocker that may be toast on Dale's car. So I left my waste on just in case that panel is toast, then we can weld it on to the rear panel.

Ahhh....I see. Sweet.