I just finished updating the services page a bit.  Added some descriptions of our work.  Check it out when you have a minute.

Make your own tools.

Voodoo Choppers has been specializing in handcrafted motorcycles since it started in 1999.  We build everything from scratch.  Fuel tanks, fenders, frames, you name it… we’ve built it.  Over the years we have acquired  a lot of different tools and equipment to help us produce high quality pieces.  One misconception about metal shaping is that you need to have a lot of equipment.  With all the bullshit on TV, many think you need a boat load of money just to get going.  The truth is, you can make many tools yourself that will help you throughout your metal shaping career

One hand tool that I find indispensable is a metal slapper.  A slapper has a long contact surface with an offset handle.  You “slap” the metal using a sliding motion.  Normally you would use a hand dolly in one hand and the slapper in the other, or you might back-up the metal work with a forming head or shot bag while working a slapper on the surface.   A metal slapper can be used while you’re shaping a piece or it’s great to use while you are welding.   Slappers are also great for “slapping” the shit out of someone.  I’m sure you can figure that one out for yourself.

A few years back I purchased a box of old files.  There was probably about forty or so files, all different styles.  Old files are perfect for making a metal slapper.  There easy to find, cheap and hardened.  For this example I made one with a compound surface using an old half round file.  Follow along and have some fun…

These old files won’t remove much material anymore, but they are great for making a slapper.  I grabbed a half round to make a compound slapper.  The finished slapper will have a gentle sweep.

After cutting off the handle with a “cut off” wheel, I chucked the file in a vise and brought out the torch.  The first bend is to make an offset for the handle.  You just need to heat up the metal, you don’t want to burn the metal.  I use about 4 or 5 inches of material for a handle.  You’ll want to adjust if you have chick hands.

Hell… maybe around 45 degrees looks good.  Were not making a rocket ship here folks.  The handle is in the vise.

After heating up the metal at the base, I start walking the heat zone up the file while pulling back on the vise grip to produce the sweep I want in the slapper face.   Don’t worry about mucking up the file teeth with the vise grip.

A little time on a sanding belt and this bitch is ready to work.  I dressed the edges of the handle and the nose.

This slapper worked well to create a concave surface in this  seat transition.

Eric

I am planning on adding a few small video clips to this are. Right now I am thinking about mostly metal shaping techniques. If you have any ideas, please let me know. I want to keep these around 3-4 minutes each.

Thanks
Eric

Blocking Hammers

Hammers are one of those tools that you can never seem to have enough of. Whether it is a body hammer or a carpentry hammer, there are so many different styles and sizes. It is easy to quickly amass a huge collection. Although I can guarantee that when you need to reach that tight pocket in a new tank design… you won’t have the right hammer. This month I am going to talk about Blocking Hammers.

In the art of metal shaping, Blocking can be considered a first step. Usually there are three phases to shaping a piece of metal; Blocking, Shrinking and Planishing. Each phase is very distinct and have specific tools to work with. The first phase, Blocking, is defining the basic shape and form of your piece. This usually means taking a rather large mallet and beating the shit out your panel. Although the practice of Blocking might look random… you better have a plan. If not, you might end up with a mess. Strategic strikes in the panel will help you advance the shape quickly and start defining areas that you will need to shrink.

While a mallet is a hammer, a mallet does not have a steel head. Knowing what hammer or mallet to use is key. Some hammers will move metal quickly, but might be to much to use with aluminum or copper. Another hammer might be great for softer material, but your arm will fall off before you start getting any shape in steel.

So I have put together a list of pros and cons that might help you decide what to use. I have ranked these in order of my personal preference.

Wooden Mallets

Pros: Available in a wide variety of materials. Something like “Lignum vitae” makes an awesome mallet. The wood is so dense it will sink in water. Wooden mallets are usually inexpensive and you can shape them very easily. You can also find them with lead centers for added weight.

Cons: You need to match up the material of the mallet with the material of your panel. A Hickory head will be great for soft material or light detailing. Some softer mallets will scar easily, which can transfer to your panel.

Steel Hammers

Pros: You can move some metal very fast with a steel Blocking hammer. It is easy make one using an old cap from a welding tank.

Cons: You can move some metal very fast with a steel Blocking hammer. They are usually expensive and not available in a wide variety of shapes. Some can be heavy and tiring to use for long periods of time.

Plastic Mallets

Pros: Available in a wide variety of shapes and sizes. They are easy to re-shape and modify. Basic shapes like a barrel is easy to find and inexpensive. Good for detail Blocking in a steel panel. Most mallets are very light. They are available with lead centers.

Cons: Specialty shapes can be hard to find and expensive. Not very good for initial Blocking. They move metal slowly.

Hopefully this will give you an idea on what to look for when you are getting ready to buy another hammer or beat on a panel.

Later

Eric

Make sure to pick up some new tees for the summer!

The Online Store just went live.  New apparel is available now and new parts will be listed soon.  Check it out and grab some gear!

An old buddy of mine interviewed me for his podcast “5 O’Clock in the morning“, make sure to check it out and learn a little about Voodoo and where we’re going.

Thanks

Eric

Well it’s been a while but finally the whole site has been upgraded and given a new look. We have updated the logo and introduced a new brand image. The galleries are full of new pictures and bikes. Have a look around and come back often. The store is almost ready to open.

Thanks
Eric

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