Metal sheet work

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Koops

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Hi everybody,
what do you normally do to replace part of the metal (car bottom) when it has a complicated form (see picture)? Is there any way to order small new parts, or a way to copy the old part in new iron sheet? I tried to make an impression in concrete, to press a new iron sheet on it by aid of a hydraulic press (35 tons) and a rubber block, but did not succeed - either the pressure was not sufficient for the whole surface, or the rubber I used was not flexible enough. I am curious for your ideas.
 

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When my son was working on mine he formed piece of metal off the vehicle as best he could then tacked it in place. Then shaped with hammer and tacking a little further. Also the real complex shapes were made out of several pieces welded together.
A ex member of this forum did a little welding for me a few years ago and he used the same method.
 
depends on how accurate it has to be compared to the original, I have a mate who fabricates one off parts using all the old school methods and he can duplicate anything such as complete front wings for a hotrod..

if I was repairing anything like your pic I would make it out of smaller parts, weld it in a bit at a time and shape as I go, or if the part doesn't need to be the exact shape I would make it as flat as possible for ease... most of the stuff I weld up only requires a similar ish profile so no problems.
 
You can get shrinker / stretchers to help with complicated shapes don't have one myself as I lack the skill to get the most out of it.
I would be making it out of smaller strips welded to form the right shape.
 

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