Yesterday we shared the first in a video series by famed sheet metal shaper Ron Covell, where he teaches a pattern making method he calls Rollation. The process is simple, absolutely makes sense once you see it, and is a killer way to make some neat shapes in sheet metal. I am watching these videos and thinking about all the times I’ve needed to fabricate something and have cut and welded way too many pieces together to get my shape, when this rollation method would have worked perfect. Well, at least now I know. If you missed Part 1 of the series, then click the link below to watch that one first.
If the name Ron Covell doesn’t mean anything to you, then you haven’t done much research or study on the topic of sheet metal fabrication. Ron is a legend in the metal working world, and has been a major player in the metal shaping industry for decades. He’s also one of the premier metal shaping instructors in the world and has classes, instructional videos, and more that you can be involved in as well. Thanks to the world of YouTube, you can also learn enough to wet your whistle by watching his videos. In this three part series, Ron teaches us about Rollation. I know, I know, it sounds like a Chad word, but it makes sense and is a great way to make accurate patterns for simple and intricate metal shaping both. In this first video you’ll see Ron making cones that could be used for all kinds of things. I see them and think shifter mount pedestal, exhaust openings, turbo or supercharger inlets, and more. These are some cool pieces I know you could find a use for. And don’t forget, these are just base shapes that can be cut and used for all kinds of things.
For fan shrouds I’ve used the same method including where the rectangle-opening end has sides both larger and smaller than the circle end, as well as there being whatever offset. If the shape is very difficult it can be made in paper and/or overlaying strips of masking tape that will later be applied to the metal part with angles and bend lines noted with a Sharpie to help at forming time. Flanges etc. can be added and marked before tin-snipping out, I imagine a dress-maker works in similar ways. A handy home remedy for when you’d like to skip CAD, and best for thin material as there will be inevitable hand-work.