Homemade Tools, Powerhouse Cover Form
 

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.:)

Re: Homemade Tools, Powerhouse Cover Form
 

What commitment! Great work Tom.

Re: Homemade Tools, Powerhouse Cover Form
 

Nice work Tom, well done!

Re: Homemade Tools, Powerhouse Cover Form
 

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.

Re: Homemade Tools, Powerhouse Cover Form
 

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

Re: Homemade Tools, Powerhouse Cover Form
 

Now you can start stamping out reproductions. :)

Re: Homemade Tools, Powerhouse Cover Form
 

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.)

Re: Homemade Tools, Powerhouse Cover Form
 

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.

Re: Homemade Tools, Powerhouse Cover Form
 

The reproduction covers are perfect and I sure couldn't make one as nice.:)

Re: Homemade Tools, Powerhouse Cover Form
 

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

Re: Homemade Tools, Powerhouse Cover Form
 

Nice work Thomas, you have the patience and good ol' American know-how to get the job done correctly!!