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Making straight cuts & smooth edges for patches

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tdskip

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So maybe the $10 tin snips from Harbor Freight weren't such a good idea, but I'm a bit at the end of my rope trying to get some patch panels cleaned up for a welding session on the TR8.

I have the basic shape down and bend with the curve of the fender but can't seems to get a smooth constant radius edge on the patch with the snips.

Should I be using a grinder or similar to get the edge right?
 
Sometimes a belt sander works nicely, depending on the shape and size of the patch. I use a good file on smaller parts, and nearly every job gets finished-up with a deburring tool.
 
I've used everything from bench grinders to cut-off wheels to small two inch sanding discs to get a nice fit. Most of my rough work was accomplished with one of those air powered body hacksaws, which works very well and very fast. I've also used snips for rough work. When doing an extensive amount of body work, air tools are almost a must.

If you are doing just a small amount of repairs, then you can make do with the snips followed by the bench grinder, and as mentioned above, a belt sander. So much depends on what the profile of the patch panel is that you are making. If you can keep the profiles simple...like a straight line...the fitting goes easier. Sometimes that not possible, but I found that inside curves on the patch panel were hardest to fit right. Try to avoid them.
 
I had to make a long straight cut today in order to cut away the bottom of a rusty door skin. I used a long piece of flat stock clamped to my door. I put one of those thin cutting wheels on my grinder and used the flat stock as a rip fence. It came out better than i could have hoped. The straight edge of my repair panel matched up perfectly for welding. I've found that a bench vice is good for flattening out bent up small patches.
 
Whoo hoo! I think I finally figured out how to make sheet metal cut using a Dremel.

Much easier than I expected actually, I ended up using a plug in (not battery) Dremel with extra strong cut off disks. I went through a LOT of disks but controlling the cut was pretty easy so it is worth the hassle and cost.

Thanks again for the coaching and support - it really makes a difference.

Now "all" I have to do is make the patch panels...
 
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