How To Smooth Out A Bulge In Sheetmetal

Cutting and welding may not be the best solution

- Ron Covell

Q. I have fabricated the rear fenders for a ’35 Ford and I want to get your advice on repairing a defect. The arrow points to an area that has too much crown, and I’m not quite sure what the best remedy is. I was thinking of cutting a slice through the center, then tapping the edges down and welding it back together. What would you suggest?

Don

Via the Internet

A. First of all, you have done an extremely nice job of making those fenders. I can tell that you are a skillful metal shaper.

Well, you certainly could make a cut through the center of the bulge, tap the edges down, and weld the joint—there is no question that it would bring down the high spot. I’d be inclined to do it another way. I’d try hammering off-dolly first. This may not work since there is a limit to how much you can cold-shrink the metal, but it’s worth a try before you “bring out the big guns.”