While we were at Grant Kustoms, we felt there wasn't a better time to have the guys there show us their craft. We were bored and wanted to see how Nissan Hardbody corner fillers were made, so Bob threw down the hammer and schooled us on the correct techniques to make metal your beeyotch.
1.First, we start with a simple...
1.First, we start with a simple paper pattern that we transfer to the sheetmetal. The original pattern is as easy as wrapping a piece of paper around the corner light and tracing the outline (always leave excess room). Using an air nibbler, the start of our corner filler is cut to size.
2.The Nissan corner is then...
2.The Nissan corner is then used to mark the center point at which the bend will take place.
3.Using the sharper end of...
3.Using the sharper end of the mallet and a sand bag to let the metal give, the metal is hammered along the line at which the corner will eventually bend.
4.The fatter side of the mallet...
4.The fatter side of the mallet is now used to smooth out the deep areas left by the other side of the mallet.
5.A foot-operated shrinker...
5.A foot-operated shrinker tapers the edge and compound curves the outer edge of the filler.
6.The ever-so-famous English...
6.The ever-so-famous English wheel now comes into play to give an even finish to the surface and smooth out all those nasty bumps.
7.The corner is now trimmed...
7.The corner is now trimmed closer to the size with some sheetmetal shears.
8.The curved sheet is now...
8.The curved sheet is now placed on a custom-made curved T-dolly to give the corner its initial bend, while keeping the curve at the peak. This part is done by hand.
9.The corner light is now...
9.The corner light is now placed inside the filler and traced to give a closer depiction of the final size.
10.Now the corner is put into...
10.Now the corner is put into the sheetmetal break to make the top body line as well as the side where the grille will meet.
11.Then the corner is relief-cut...
11.Then the corner is relief-cut to bend in the bottom edge, and the corner bend is pulled over by hand and put into the hand-operated shrinker to add that important curve.
12.Next, the top is relief-cut...
12.Next, the top is relief-cut to add the top body line.
13.Using a set of wide-billed...
13.Using a set of wide-billed tongs, the top body line is bent over.
14.Once again we trim the...
14.Once again we trim the excess material off, and get closer to our goal of the perfect Nissan corner filler.
15.The seams are now welded...
15.The seams are now welded into place to help retain the correct shape of the filler.
16.The seams are ground down...
16.The seams are ground down with an angle grinder with a 40-grit flap disc to give the corners a finished appearance.
17.The last of the trimming...
17.The last of the trimming is done to get the corners to their final state and ready for installation.
18.Here is our finished product...
18.Here is our finished product matching the factory corner light perfectly. Next time you wonder about the price of a handmade taillight or corner filler, we hope this gives insight into the knowledge, skill, and time it takes to pull off such a simple-looking item.