PANELBEATING

A GUIDE TO

WHEELING

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CONTENTS

Page

Wheeling Machine
Synopsis
Hints
Itemised Body Mock Up
Ovolo
Concave Return
Beaver Tail
Cant Panel D
Cant Panel E
Collar for Coupe
Morris Minor Rear Door
Morris Minor Front Door
Humber Door Panel
Mini Minor Side Panel
Test Questions
Fitting of Platen Wheels
Striking Curves

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1 Main Frame - All steel boxed section design, reinforced and
continuous welded.

Main spindle accurately fabricated into the machine.

2 Large Wheel - Mehanite cast iron 200mm dia x 75mm heavy duty ball
bearings. Wheel is ground after assembly to ensure accuracy and
finish.

3 Small Contoured Wheel - Mehanite cast iron 75mm dia x 75mm, 4

off in assorted shapes, fitted to their own shafts, machined and
finished as per large wheel.

4 Box container - Welded steel, to house these wheels is provided, with

racks to suspend the wheels in clean oil.

5 Pressure Jack - All steel is operated with non slip foot control,
allowing hands to be free for work positioning.

6 Small Wheel Mounting - Has bronze adjustable slide for positioning

working surfaces of small wheels.

6A Ratchet Handle - To assist in processing small work.

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DEFINITION OF WHEELING

The passing of a sheetmetal panel from end to end between hardened steel
rollers or wheels superimposed on each surface under applied pressure, so
that the wheel tracks traverse the entire area of the panel.

Close or overlapping tracking tends to a higher crown or contour, therefore

open or parallel tracking makes to a lower crown or contour.

In either case, the result is a “crowned” or domed panel.

APPLICATIONS

This basic definition is not the sole employment for a wheeling machine, nor
the limit to the shaping possible upon it; likewise the planishing of damaged
panel work on this machine can effect savings in time with superior finish and
it is fair to state, that the shaping - either partially or wholly - of flat stock sheet
into almost any compound shape can be accelerated by intelligent use of the
wheeling machine.

To summarise, the applications are:

1 To shape flat stock to desired contours

2 To planish shapes formed by percussive (hammered) working
3 To reshape and/or planish existing panels in damaged condition.

BASIC TECHNOLOGY

Wheeling machines, in the main, differs only in the construction materials,

though there are some features of design to consider.

One well known imported model features a heavy cast frame of rigid design
(cast iron exhibits “dead” characteristics - ie no elasticity) and refinements like
a cam manipulated die roll crutch and lever assisted pressure adjustment.

Locally built examples are of fabricated steel - either plate or joist section -
and most seem to favour a lower panel height than does the imported
machine. Many panel men prefer this on the ground of lessened should
fatigue.

Either type competently used, can produce perfect panels, preference for
either one must be based on individual requirements or other considerations.

The platen wheel in some models is keyed to a shaft mounted in two widely
located ball races in the frame; pressure strain is thus transmitted directly
into the frame where it can be countered by the frame design.

Other proprietary models encase the ball races in the platen wheel itself, this
being mounted on a stubby fixed axle or spindle, where this is carried into the
frame, the result being much the same as before.

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On the other hand, where this spindle is simply welded to the nose of the
frame, the design as such becomes virtually ineffective since the tendency is
for the load to concentrate on the spindle base.

Die rolls are ball bearing and usually supplied in sets of four track widths
ranging from 25mm at No 1 to approximately 10mm at No 4.

As track width decreases, so more relief is provided, on the die rolls, at the
shoulders to effect work clearance.

BASIC SHAPES

Before concerning ourselves with techniques, some basic conception of

shapes must be defined, somewhat as follows:

SIMPLE CONTOUR Any panel such as:

a) A straight forward crowned surface, to a lessor or greater degree, eg

turret panels and simple door panels.

NOTE: Most body panels are crowned, no matter how flat they may
appear to be.

b) A panel of extreme contour, if the working is all in the same plane.

COMPOUND CONTOUR Any panel comprising a number of shapes such

as:

a) Certain pre-war shapes and most certainly quite a few post-war

models of cars with door and side panels, also rear panels,
transforming from a crowned panel through to a concave or return
panel

Also in certain cars the transformation is quite pronounced, eg Morris

Minor, Morris Oxford, Javelin, in the boot doors on some of the earlier
cars.

b) An uncomplicated return panel (concave transversely but crowned

longitudinally) which while technically compound is so easily produced
as to seem to be a simple Contour.

TECHNIQUES

Pass, Track or Tracking is meant to explain the motion or movement of the

die rolls moving from end to end along the panel.

Shaping of simple contours is easy enough, requiring only that the roll tracks
on each pass should run closely alongside each other, if not in fact, overlap,
depending on the crown required and of a terminating close to the ends of
the panel.

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FAULTS

On simple panels are initiated by any, or several of the following:

1 Incorrect die roll for the stage of working

2 Incorrect roll pressure and/or alignment
3 Slackness in manipulation of panel
4 Irregularities on die roll surface.

CONSIDER THESE IN DETAIL

1 The No 1 die roll is a tool in its own right, nor primarily to be used to
smooth panels which have been roughed out by:

a) die rolls having greater curve ie No 3 or No 4 rolls

b) panels which have been blocked or hammered out.

The No 1 roll should be used for door panels, turret roofs or similar low crown
panels.

The No 1 roll has certain limits to what it can do, as far as crown goes on a
panel, usually 50mm in say a turret roof of 900mm x 750mm or about 25mm
in 300mm x 300mm.

No 1 roll is usually called the “flat” roll, is not too slow as is sometimes stated:
with proper pressure adjustment, on the die rolls, it is quicker to wheel a turret
roof with No 1 roll than with No 2 or No 3 rolls, mainly because the panel
keeps reasonably flat while working and does not acquire a series of ridges
as is likely with No 1 or No 2 rolls.

TO SUMMARISE

No 1 rolls for low crown panels

No 4 roll for high sharp crowns

No 3 and No 4 rolls for intermediate crowns

Therefore use correct die rolls for the work in hand. This knowledge will
come with experience.

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2 Incorrect roll pressure may be harmless or otherwise ie lighter
pressure causes no faults, it simply slows up the work, whereas
excessive pressure leads to trouble the nature of which depends some
extent on the particular die roll in use.

Three conditions caused this way are:

a) intensive ridging, narrow tracked rolls

b) a roll or hump at each end of the panel, can also be caused by faulty
manipulation

c) wavy from end to end, tracks not spreading sufficiently.

3 Sloppy manipulation.

a) On simple panels, excessive lowering of the panel as it approaches

either or both operators, this causes an abrupt hump or bump in the
panel end furthest from the negligent operator.

b) Divergent roll tracks, or fan shaped tracking, causing a tight spot at

one end. Faulty guiding.

Axiom: Each man pulls and neither pushes.

4 Irregularities on die roll surface.

a) Usually only oil or grease exuded from the panel by pressure, easily
wiped off with any turps rag or kerosene rag.

b) Damage caused by improperly treated panels, welds not properly

cleaned off, road dirt, old paint and scale left on.

BASIC SHAPING TECHNIQUES

a) Simple contour

b) Concave or return panel

c) Compound

OPERATING TECHNIQUES

1 Single Operator, two methods:

Normal Stance - Panel to be held as near to centre of edges as

possible to prevent whipping.

With lengthy or narrow panels, control cannot be exercised upon line

of entry to the wheel without tending to promote whip, thus in avoiding

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 this condition a curve profile results which is characteristic of this
technique.

Traverse Stance - The operator stands before the machine, holding

the panel by the ends and passing it through laterally.

2 Two Men Operation

This is essentially a teamwork operation and for best results these

facts should be considered:

A rhythmic action must be established for any given panel and for this
reason it is advisable that both operators be of comparable height.

The operating principle should be clearly understood, ie each man

pulls and neither pushes, the only skipper like decision required of any
one operator being the extent of contour desired.

OPERATING PRINCIPLE

From the sketch it can be seen that at the moment operator (a) has all
the leverage and therefore has merely to twitch the panel the small
amount necessary to line up the next pass. Whereas if operator (b)
attempted to do so he would have to move the entire panel likely
against the momentary resistance of (a)’s grip as well and do it all from
the pivotal centre of the platen wheel.

Governed by the laws of leverage, this requires many times the effort
that (a) would expend and with nothing like the same accuracy.

(b)

Operator (a)
lines up for (b)
to pull through

(b)
YOU MUST ENSURE THAT:

1 All panel edges are free from burrs and rags

2 Panels are thoroughly clean and free from oil and dust etc

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3 Die rolls are the correct shape in relation to the panel

4 Die rolls are perfectly clean

5 Platen wheel is perfectly clean

6 Tracking alignment is constantly checked

7 Panel is always level at the point of wheel contact, (unless special

shaping is intended

8 Panel end is not dropped (single or double operator)

9 Gloves are worn

10 You are concentrating on your work, do not be careless, you cannot

whistle, sing or talk at the same time

11 No fooling around occurs; a good job can be spoilt by one instant of

fooling

12 Your panel follows the line of curve in travelling between wheels

13 The panel is not twisted

14 A wheeling pass is not haltered before completion, this can cause a

nasty little bump which is not easily erased

15 Rough welds must not be passed between wheels, in fact nothing

must be passed between the wheels except panel metal in good condition.

Intense pressure on a piece of wire for instance, can completely ruin

the wheels

16 It is better to begin with to be light on the die roll pressure, than to be

too heavy

17 Take your time, be patient, be confident and be careful while you are
learning

18 Observe the above points and success will follow.

BUMPS AND HOLLOWS OR CORRUGATIONS

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Usually occurs in a one man operation.

The operator holds one end only and as the panel is pulled towards him, it
usually starts to vibrate causing “whipping”, which in turn causes the humps
and hollows to form from the uneven wheeling.

This may also be caused by a platen wheel or a die roll being out of true.

A die roll is usually 65mm to 75mm in diameter; any irregularity of circular will
show at approximately every 200mm.

A platen wheel is usually 200mm in diameter and any irregularity will tend to
show at approximately 600mm.

TREATMENT

The operator stands traversely to the wheeling machine, with a hand on each
end of the panel, or, alternatively takes a partner to handle the other end of
the panel.

If corrugations persist, change either die roll or platen wheel.

TRAVERSLY OR ONE MAN OPERATION

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Operator stands opposite to end of the wheeling machine, so that he can hold
the panel in each hand as shown above.

Care should be exercised, as often one hand has a tendency to drop a little
lower than the other, causing a hump or gathering at the other end.

WHEELING - FULLNESS, CAUSING HOLLOW

When a crown is formed in the area A-A and B-B, this creates an uneven
distribution of metal over the whole panel and thus causes a hollow to form in
the area B-B and C-C.

TREATMENT

With the same pressure on the die roll, continue to wheel through from B-B to
C-C, until curve is even. Then check that the general curve is correct.

PANEL TOO FULL ON ONE SIDE

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Panel is too full in area A-A and B-B.

TREATMENT

Commencing at B-B, medium die roll pressure, open track wheel toward A-A,
gradually closing track. The edge A-A must be stretched. Repeat if
necessary.

NOTE: Procedure can be reversed if necessary, stretching edge A-A,

closed track, gradually opening to B-B.

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LONGITUDINALLY DIAGONAL OFFSET TRACKING

Mainly, the contributing factor in this type of wheeling fault, is unfamiliarity, or

very little knowledge of the wheeling machine.

In this case both operators neglected to ensure overall an even tracking,

especially parallel tracking.

FAULT

Commencing at 1 through to 2 then down to A, using A as centre, wheeling

fan shaped from 2 to B. With B as centre wheeling fan shaped from A to C,
repeating with C and D. This fault is hard to rectify in a panel; this is a
suggested method.

TREATMENT

Put through rollers (not wheeling machine) 3 or 4 times, until the panel is
formed into a cylinder, then roll out until fairly flat.

This should relieve any unevenness in the panel. Check panel for correct
shape. Ensure tracking is even and parallel.

WHEELING - EDGE TOO LOOSE

Most times caused by stretching the edge.

TREATMENT

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Starting at A-A approximately 25mm in from edge, commence wheeling,
medium die roll pressure, towards B-B. Close tracking at A-A and gradually
opening track towards B-B.

You must keep off edges A-A and B-B.

Check curve for evenness, correct if necessary.

NOTE: You can if you wish, start at B-B and work through to A-A using
reverse procedure.

LONGITUDINAL HOLLOWS AND/OR BUMPS AT ONE END

Fullness at A-A caused by operator “B” dropping his end of the panel below
the line of the regular curve.

This fullness can also be caused by operator “B” stopping short at A-A.

The ridges shown at C-C-C are caused by uneven wheeling or tracking.

TREATMENT

Operator “B” must ensure his end is in line with the curve of the panel: also,
he must run his end right through A-A to assist in removal of gathered or
excess metal.

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Both operators must ensure level and even as well as parallel tracking, but
where you already have ridges in your panel:

Slightly slacken die roll pressure

Commence wheeling at top of ridge, open tracking
Gradually closing track to bottom of ridge or hollow
Then opening track to top of other ridge
When satisfied as to curve, planish off panel

But: Make sure tracking is even and parallel.

HUB CAP OR SIMILAR

Wheeling should continue around the disc as at B, by doing this you will
create an even curve or contour.

Wheeling as at A will tend to give an uneven curve or contour.

In hub cap A the tracking is continually crossing or overlapping in the centre

of the disc thereby causing a peak or raised portion in the hub cap.

PANEL TWISTING IN LENGTH

Twisting is caused by passing or tracking too quickly over area B-B.

Uneven wheeling, over the area B-B also results in twisting.

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TREATMENT

Light wheeling over the are B-B, usually rectifies such twisting.

Care should be exercised as too much pressure and wheeling could spoil the
panel.

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(A) Concave ‘return’
Wheeling, Rolling,
Folding, Crimping.

(B) Beavertail
Compound, crowned
& Concave, Wheeling,
Folding & Crimping.

(C) Collar
Sandbag and block
work and/or
Wheeling & Welding.

(D) & (E) Cants

Wheeling only.

PROJECT NO 1 OVOLO PANEL

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OVOLO PANEL - ALTERNATIVE METHODS

PROCEDURE

1 Mark off bottom edge at 50mm and 75mm

2 Fit No 4 wheel to machine

3 Using pressure, stripe between 50mm and 75mm line

4 Change No 4 wheel to No 2 wheel

5 Starting at A-A

6 Use open track and gradually close track

7 Stop at striping

8 Planish with No 1 wheel, finished with wheeling

9 Fit into rollers, to bottom of striping

10 Have handle held to prevent turning

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11 Press panel upwards to slightly over square

12 Remove panel

Panel complete except for folding if and where necessary.

NOTE ALTERNATIVE METHODS.

POINTS TO WATCH FOR

Die rolls clean and level

Eveness of tracking
Stripping, sufficient for job in hand ie Deep and wide enough
Straight along bottom edge.

SAFETY HINTS

File all edges. (burred and sharp edges cause cuts)

Clean panel properly
WEAR GLOVES AT ALL TIMES.

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CONCAVE RETURN

This panel has a curvature both ways ie A-A and B-B.

The object in this exercise is to make the line of the panel along A-A and B-B
curve without too much raising along the mean centre.

Pressure on the wheels should be light rather than too heavy.

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PROCEDURE CONCAVE RETURN

1 Consider the panel divided into 3 along its length

2 Fit No 1 wheel to the machine

3 Adjust wheeling pressure, appropriate to job in hand

4 Starting at edge A-A, commence wheeling

5 Using close tracking, gradually open tracking to centre

6 Work through centre, gradually closing track towards B-B

7 Finish along edge B-B

8 This should give two loose edges, slightly wavy and a slight curve
along the mean length

9 Panel can now be rolled to shape

10 Slacken roller pressure right off

11 Screw back roller right down

12 Roll panel in, along length, to half way

13 Roll panel out, pressing down to get correct curve

14 Turn panel around, repeat process

15 Check for fit, correct if necessary

16 Mark and fold

17 Crimp to get correct curve along rails

POINTS TO WATCH FOR

Die rolls clean and level

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Tracking straight and even as required
Panel not being dropped at one end
Panel not being lifted at one end
Careful, not too much pressure.

SAFETY HINTS

File all edges (burred and ragged edges cause cuts

Clean panel properly
WEAR GLOVES AT ALL TIMES

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BEAVER TAIL

A compound panel, entailing Crowned and Concave wheeling.

This panel has a crown or rounded or raised shape in the area marked C-C to
1-1.

In the area marked 1-1 to 2-2, this is the transition part of the panel, being
neither crowned or concave (returned).

The area marked 2-2 to D-D is the concave or returned area.

BEAVER TAIL

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1 Divide panel into three, as marked 1-1 and 2-2

2 Fit No 1 or No 2 die rolls into wheeling machine (see below)

3 Adjust wheeling pressure appropriate to job in hand

4 Approximately 25mm in along edge C-C, commence wheeling

5 Use close tracking and nearing line 1-1 commence open track, to
through 1-1, open tracking

6 Nearing No 2-2 line commence closing track, gradually overlapping

to edge D-D

7 This should give a loose edge along D-D

8 Help from rollers

9 Slacken roller pressure screws

10 Turn panel upside down ie area enclosed in C-C and 1-1 shows as a
hollow

11 Fit edge D-D into rollers, to approximately half way

12 Turn out very slowly

13 Commence to press panel down after it starts to roll out

14 Check for fit, correct where necessary

15 Mark, cut and fold

16 Crimp to get correct curve along rails

POINTS TO WATCH FOR

Item No 2 above Die roll No 1 gives smooth finish, but a little slower

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 Die roll No 2 is quicker but as good a finish usually not
obtained
Panel level, not twisted
Tracking straight and even
Panel not being dropped or lifted at one end
Die rolls clean and level

SAFETY HINTS

File the edges (burred and ragged edges cause cuts)

Clean panel properly
WEAR GLOVES AT ALL TIMES

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CANT PANEL D

This panel, most shape in the area bounded by the numbers 1 - 2 - 3 - 4,

dispersing towards G.

This shape or fullness is worked out to the edge F-F.

Care should be taken not to make the area along F-F too full.

CANT PANEL D

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1 Divide panel as marked

2 Fit No 3 die roll to wheeling machine

3 Adjust wheeling pressure to job in hand

4 Commence wheeling in area bounded by Nos 1-2-3-4

5 First lengthways, close tracking

6 Disperse approximately every 3rd track towards G

7 Now cross tracking area bounded by 1-2-3-4

8 Close tracking, disperse approximately every 3rd track towards E-E

9 A slight curve inwards should now be forming along F-F

10 Commence from 1-4 through to G, wheeling reasonable close tracking

to F-F

11 For further development of cant panel, such as raising etc, check

directions 3 to 11

12 Some bending over a pipe or other type of former may be necessary to

finish shape

13 Planishing can be effected with Nos 2, 3 or 4 die roll

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POINTS TO WATCH FOR

Die rolls clean and level

Panel properly clean (grease, rust etc removed)
Panel not too full along edge F-F
Loosen (stretch) edge along F-F, if this is so
No 2 die roll and diagonal tracking gives finish
Check for die roll marks, plainish out

SAFETY HINTS

Wear gloves at all times

File all edges (burred and ragged edges cause cuts)
Don’t be careless
Clean panel properly
WEAR GLOVES AT ALL TIMES

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CANT PANEL E

This is a complicated one, involving full crown in area 1-2-3-H and a return or
concave in area 1-2-4-H, while the area 4-2-3-I-I is only slightly curved along
its length I to I.

Work is mainly with No 3 and No 4 die rolls, but plainishing can be carried out
with No 2 die roll, using diagonal wheeling.

The area bounded by 1-2-3-H requires quite a crown, lightly dispersed over
line 1-2,

In acquiring the crown there is liable to be a gathering of metal towards H-3,

disperse this gathering by starting about 65mm in open tracking and
gradually closing to over-lapping to edge H-3-1.

Repeat if necessary.

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CANT PANEL E

1 Divide panel as marked

2 Fit No 4 die roll

3 Adjust pressure, appropriate to job in hand

4 Commence wheeling in area bounded by 1-2-3-H

5 Mainly along 2-3 dispersing towards 1-H

6 Wheeling can be lengthways, crosswise, diagonally or combination of

all

7 When considered sufficiently raised, (but possibly not enough)

8 Commence wheeling along 4-2-3 out to I-I, with slightly more tracking
along 2-3

9 Avoid stretching edge I-I too much at this stage

10 Change die roll to No 3

11 Adjust pressure, reasonably tight

12 Starting approximtely half way between No 4 and No 2

13 Commence wheeling, towards No 4, short strokes open track gradually

closing

14 Nearing No 4, longer strokes, gradually over lapping (see note below)

15 Planishing can be carried out with No 2, 3 or 4 die rolls.

POINTS TO WATCH FOR

Note for No 12: It is better to turn panel upside down to fit die roll

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 Die rolls clean and level
Avoid too much fullness too early
Be sure your panel is clean, edges filed, no ragged parts

SAFETY HINTS

Do not be careless
WEAR GLOVES AT ALL TIMES

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COLLAR FOR COUPE

This panel can be obtained, using different methods or techniques and with
an equally good finish, whichever method is used.

To name one or two methods:

Blocking out: this method is very effective, but can be hard and slow work

Fitting “vee” pieces: welding them in and then blocking the panel out. This is
sloppy workmanship and does not engender a good finish.

Wheeling This gives a good general finish and as our programme so far has
been on wheeling, we will continue our programme as such.

It will be necessary to make this project in two parts.

A paper pattern should be marked out for the side (C) 1, leaving
approximately 25mm allowance all around, this should be laid on the panel
and cut out.

Panel (C) 2 can be cut out without a pattern, measuring will be sufficient, with
allowances on the panel to be cut out.

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COLLAR FOR COUPE

1 Make pattern of (C) 1

2 Fit No 2 roll to wheeling machine

3 Adjust roll pressure light to medium

4 Wheel whole panel in direction 3 to 4

5 Remove No 2 roll and fit No 4 roll

6 At point “X”, commence wheeling using medium pressure

7 Open track starting at X-Z and closing to overlapping at 6_y

8 Keep a slight pressure down at No 4

9 Repeat as necessary to bring shape required

10 No 2 and No 3 roll could be used to relieve certain places

11 (C) 2 panel is rolled to shape, to fit frame

12 The area adjoining 6-Y should be treated as in Nos 7, 8 and 9

13 Some hand bending will be necessary in places

14 Fit the two pieces (C) 1 and (C) 2 frame

15 Mark for welding, remove from frame

16 Cut off excess metal and tack weld

17 Smooth tack welds and complete welding

18 Smooth welding and complete panel

POINTS TO WATCH FOR

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Die rolls clean and level
Keep check for correct pressure
Watch tracking alignment

SAFETY HINTS

File all edges (burred and ragged edges cause cuts)

Clean panel properly
WEAR GLOVES AT ALL TIMES

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MORRIS MINOR REAR DOOR

This is a compound panel, involving a crowned (raised) area and a concave

(return) sweep.

This panel requires some thought before wheeling commences:

Where to start?
Which die roll or rolls to use?
How much pressure to use on the die rolls?
What technique to use?

The fore going really depend on the individual and his experience.

Tentatively, this panel should be shaped, using a No 1 die roll throughout.

Close tracking between 1-1 and X-X, gradually opening tracking from X-X to
Y-Y.

Then from Y-Y start closing track quickly to overlapping along edge 2-2,
making this edge 2-2 fairly loose.

The area enclosed by the figures Y-Y and 2-2 can be rolled over a former, or
curved in the rollers.

The panel should be swaged before folding and/or crimping.

Care should be taken not to fold along the line 2-2, over much. The first fold
should be such that the panel is parallel with the ground, the second should
then be folded at right angles to the first fold.

The swage should now be put in, the top folded and crimped.

The panel should be frequently checked for fitting on frame.

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MORRIS MINOR REAR DOOR

1 Fit No 1 die roll

2 Adjust die roll pressure, medium to slightly heavy

3 Start wheeling inside edge No 1-1, close tracking

4 Approaching line X-X, gradually open track to Y-Y

5 From line Y-Y commence close tracking toward edge 2-2

6 Approaching edge 2-2 commence overlapping tracks

7 This gives a loose edge along 2-2

8 This loose edge helps make the return

9 Now for the rollers, pressure screws tight, then loosened 2½ turns,
back roller right up

10 Roll loose edge into rollers, crown side up, to approximately 200mm

11 Assistant starts rolling panel out, very slowly

12 Tradesman, with hands on either edge, starts pressing panel up

13 This should be done carefully and evenly

14 Check for fit and correct where necessary

15 Swage panel, keeping an even curve

16 Fold and crimp where necessary

CHECK FOR:

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Insufficient crown
Twisting caused by insufficient wheeling in the return
Too much wheeling can spoil the panel so care is necessary

FILE THE EDGES EXERCISE CARE WEAR GLOVES AT ALL TIMES

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MORRIS MINOR FRONT DOOR

1 This panel is a carry on from the Morris Minor rear door panel.

2 The guard extension part is marked out with a full sized pattern and
then cut out 25mm” inside the marking. This is to allow for the flange
for welding the bulge or guard extension to the door panel.

The flange is made completely on the wheeling machine.

Care should be taken not to force the flange too much.

At “A” the flange should be almost at right angles, at “B” slightly less, at
“C” should be less still, while at “D” the panel should be flat.

Check at “E” to see if it fits on the frame and also at “D”.

POINTS TO WATCH FOR:

Die rolls clean and level

Panel properly clean
Not too full along fold at “B”
This panel can also be worked from the other side, in which case the fold line
would need to be marked 25mm in.
WEAR GLOVES AT ALL TIMES

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MORRIS MINOR FRONT DOOR

1 Panel marked and cut out

2 Folding line to be very clear

3 Fit No 1 die roll

4 Adjust die roll pressure, medium

5 Usually commence at A

6 Fit panel so that should of platen wheel is level to folding line

7 Slowly and gently move panel along edge

8 Move 150mm to 200mm and then back

9 Move forward again to about 250mm

10 Keep pressure upwards at F

11 Gradually move right around edge decreasing angle of bend in

progress

12 Check fit at A and E first, correct if necessary

13 C needs to be checked also and possibly a cold shrink will be

necessary in flange

SAFETY HINTS

Clean panel properly

File all edges (burred and ragged edges cause cuts)
Make “CAREFUL” your watch word
WEAR GLOVES AT ALL TIME

MORRIS MINOR FRONT DOOR

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1 Panel marked and cut out, including folding line

2 Folding line marked on under side of panel, very clearly

3 Fit No 1 die roll

4 Adjust die roll pressure, medium

5 Fit edge of panel so that shoulder of platen wheel is level with folding
line marked under side of panel

6 Usually commence at A

7 Slowly and gently move panel along cut out edge

8 Keeping steady pressure down at F

9 Move 150mm to 200mm toward V and then back

10 Move forward again, then back

11 Gradually move right around the cut edge in this manner

12 Decreasing angle of bend in progress

13 Check fit at A and E first, correct if necessary

14 C needs to be checked also and possibly a cold shrink will be

necessary in the flange

MORRIS MINOR FRONT DOOR

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1 Fit No 3 or 4 die roll

2 Check die roll for level

3 Adjust die roll pressure to approximate medium

4 Commence wheeling in area A, B, C raising area considerably

5 This will cause a concave area to form toward D and E

6 Careful wheeling from BC to DE will eliminate this concave area

7 The elimination of the concave area may require that more wheeling
be done in the area A, B, C

8 The triangle bounded by A, B, C must have a fairly full crown

9 When satisfied as to fit and shape, planish panel

10 Fit No 1 die roll

11 Check for level, pressure light

12 Diagonal wheeling has tendency to keep panel shape and eliminate

ridges

13 Fit panel, scribe for welding, trim and weld

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MORRIS MINOR FRONT DOOR

This panel needs considerable wheeling in the curved area, shown as A, B, C

with the use of No 3 or 4 die roll

Usually when wheeling in a concentrated area, as in this case, the panel

takes a concave shape, as with BC to DE

This will required careful wheeling down towards DE from above BC. Do not
stretch edge A-B. Check the fit on the frame.

With panel fitted on frame with vice grips, turn the whole job over and mark
for welding.

POINTS TO WATCH FOR:

That guard extension fits snugly to main panel when scribing

The cross scribe line is clearly marked
No loose edge from D to E
That both panels are fitted properly
Both Panels are firmly fixed, before scribing
Keep scriber square to panel during marking

SAFETY HINTS

File all edges (rough edges can cut)

This is a one man operation therefore you are the only one liable to be
hurt. Do not be careless
WEAR GLOVES AT ALL TIMES

HUMBER DOOR PANEL

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This panel requires carefully spaced wheeling tracks or passes.

Close tracking along line B-B, slightly below but mainly above the line B-B,
preferably using a No 2 or 3 die roll.

Change to a No 1 die roll. Commencing at line A-A and moving down the
panel towards D-D but not stretching the edge, as we wish to retain the shape
or crown.

The sharp folds are made in the folders and while held there are shaped by
hand ie the curves.

POINTS TO WATCH FOR

Close tracking and open at right places

Curves in hand folding right
Striping full enough to make curve
Panel not hollow between B-B and C-C
No twist in panel, usually caused by insufficient shape

SAFETY HINTS

Do not catch your hands in wheeling machines

File all edges of panels
Do not fool around
Do not get careless
WEAR GLOVES AT ALL TIMES

a:aw:aw:wheeling 43
HUMBER DOOR PANEL

1 Fit Nos 2 or 3 die roll

2 Check for level

3 Fairly heavy striping along line B-B

4 Keep slightly below B-B, then mainly up towards A-A

5 Fit No 1 die roll, check level

6 Start at A-A, open tracking quickly closing track toward B-B

7 Opening track towards C-C and quickly closing track towards D-D

8 Areas enclosed by CC - DD and AA -BB, should now have fair crown

9 Place panel in folders, upside down at B-B

10 Fold to about 1500mm and then press panel down gripping at C-C

11 Turn panel correct way up, fit A-A in 25mm and fold to nearly 90°

12 While still in folders press firmly down making a full curve

13 Bottom D-D is placed in folders 25mm and pressed upwards making a

full curve

POINTS TO WATCH FOR

There is sufficient crown in panel before any folding operation. Some

buckling may occur about B-B, this usually disappears when curved.

SAFETY HINTS

File your panel edges (ragged edges cause cuts)

WEAR GLOVES AT ALL TIMES
MINI MINOR SIDE PANEL

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This panel should be marked out, with a pattern on a sheet of panel steel, but
not cut out until the panel is wheeled to shape, or wheeling is completed.

Start approximately 75mm in from top at A-A, very close tracking to B-B and
then gradually opening track down to C-C at bottom of panel.

A No 2 die roll can be used but preference should be given to a No 1 die roll
as it gives a better finish and less work.

The area between A-A and B-B should have a fairly good crown,
approximately 10mm - 12mm over the whole length, gradually diminishing
towards C-C.

When finished wheeling, the panel should be rolled, to assist the shape, Then
folding carried out (before or after cutting out).

After cutting the panel out, the 12mm flange is turned in to fit around the door
pillar and turned out on the bottom, the wheel arch and back corner, for ease
in attaching to side of body.

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MINI MINOR SIDE PANEL (WHEELING)

1 Panel marked out on panel steel as shown

2 Do not cut out until wheeling completed

3 Fit No 1 or 2 die roll

4 No 1 die roll preferred, medium pressure

5 Start approximately 75mm in from top at A-A

6 Close or overlapping tacking towards B-B

7 Gradually opening tracking towards C-C

8 Check shape, end to end, with a straight edge

9 There should be approximately 10mm or 12mm at each end

10 Assist shape by rolling, starting at C-C

11 Gradually increase curve at B-B to A-A

POINTS TO WATCH FOR

B-B to C-C fairly flat

That wheeling is not too abrupt at A-A
75mm is only approximate
Be very careful not to cut panel out before wheeling
Tracking should be even to avoid ridges

SAFETY HINTS

Panel clean
File all edges (ragged edges cause cuts)
Do not fool around
Carelessness causes accidents
WEAR GLOVES AT ALL TIMES (helps to prevent accidents)
MINI MINOR SIDE PANEL (FOLDING)

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All folding lines should be shown and allowed for on the patter ie hand folding
around wheel arches, rear corner and other pertinent places.

Long machine folds should also be marked clearly.

SAFETY HINTS

Do not be careless
File edges of panel, cuts can hurt
Watch what you are doing, not what the other fellow is doing
WEAR GLOVES AT ALL TIMES

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MINI MINOR SIDE PANEL (FOLDING)

1 First fold is at No 1-1

2 Fold till panel is parallel, approximately to ground

3 Remove panel

4 Lower folder approx 4.5mm or 6mm

5 Turn panel over and fit in to No 2-2

6 Fold to right angles

7 This should give a nice small round fold

8 Crimp along top edge, from A-A, causing a curve of about 10mm to
12mm from end to end

9 Readjust folder apron

10 Place panel, right side up into folders to No 3-3

11 Fold to right angles

12 Cut panel out to correct size; hand folding allowances etc

13 Fold all other edges by hand.

POINTS TO WATCH FOR

Do not drop one end

Wheel evenly
Hand folded edges should be nicely squared
Check all curves
DO NOT CUT PANEL OUT BEFORE WHEELING
QUESTIONS & ANSWERS

Q What is the definition of wheeling?

a:aw:aw:wheeling 48
A The passing of a sheetmetal panel from end to end between two hard
steel rollers, superimposed on each surface under applied pressure,
so that the wheel tracks overlap and traverse the entire area of the
panel.

Q What are the applications of the wheeling machine?

A (1) To shape flat stock to derived contours.

(2) To planish shapes after percussive working.
(3) To reshape and/or planish existing panels in damaged condition.

Q What is a platen wheel on a wheeling machine?

A The top or larger wheel, usually about 200mm diameter and 75mm
across and superimposed , or fitted over top of the die roll.

Q Sketch a good design of platen wheel fitted to a wheeling machine.

A See separate page.

Q (1) How many types of die rolls are usually supplied with a wheeling
machine?
(2) Make a sketch showing the different types.

A (1) Four
(2) See separate page

Q What is the limit of any die roll ie the amount of curve

A When the panel starts to rub on the shoulders of the die roll

Q What effect has too light a pressure on a panel?

A None. It simply slows up the work.

Q What effect would a number four die roll have on say, a low crowned
door panel?

A (1) Intensive ridging, not desirable in a panel of this type.

(2) A roll or hump at each end of the panel.

Q What is the first care when wheeling a damaged panel ie a mudguard

or similar type of panel?

A Remove all paint and road dirt, underseal etc.

Q What is the first care when wheeling a welded panel?

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A To forge down all knotty welds ie welds with too much wire,
overlapping or bad welds. Cleaning off with a sanding machine is not
usually good enough.

Q What could be the effect on a long narrow panel when wheeling from
one end only? (Single operator).

A The panel would tend to whip, thereby causing buckling.

Q What is meant by transverse stance?

A The operator stands before the machine, holding the panel by both
ends and passing it through laterally, the work proceeding to the panel
edge or as required by the operator.

Q For top line results what important factors should be considered when
wheeling?

A (1) A rhythmic pacing action must be established.

(2) If possible both operators should be of similar height.
(3) The operating principle should be clearly understood eg each man
pulls, neither pushes.
(4) Whom will decide as to the amount of crown or contour required?

Q A panel has too high a crown, how could this be corrected?

A By applying appropriate pressure on the die roll already in use starting

from the middle of the crown open tracking, gradually closing track to
outside edge, same for other side and repeat as necessary.

Q A panel has an uneven concentration of wheeling (divergent tracking)

what is the cause of this?

A Faulty manipulation, usually caused by one operator working against

the other ie trying to guide the panel while other operator is pulling.

Q What is the technique in making a concave or “Return” panel?

A Commence wheeling at an outside edge, tracks overlapping from end

to end, making a minimum number of passes in the centre and working
to the opposite edge, so that the tracks commence to overlap again.
Repeat as necessary.

Q What is meant by a “Return” panel?

A A panel which is concave transversely, but crowned longitudinally.

Q What is meant by a simple contour?

A (1) A straight forward crowned surface such as, turret panels, or

simple door panels.
(2) A panel of extreme contour, if the working is all in the same plane.

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Q What is meant by a compound contour?

A Any panel comprising a number of shapes such as Morris Minor,

Morris Oxford or Javelin door panels.

Q What is meant by a “Pass or Track”?

A A single stroke or roll track from end to end of a panel.

Q Name three faults occurring on simple contours.

A (1) Incorrect die roll for the stage of working.

(2) Incorrect roll pressure and/or alignment.
(3) Slackness in manipulation of sheet.
(4) Irregularities on the die roll or platen wheel surface.

Q Name two factors which can cause buckling in a panel approximately

every 225mm - 250mm.

A (1) Too higher pressure on the die roll, by not allowing the panel to
curve buckling occurs.
(2) Dirt on the die roll.
(3) Die roll worn or out of centre.

Q If buckling occurs say every 625mm or 650mm what could be the

cause?

A (1) Dirt on the platen wheel.

(2) Platen wheel worn out of centre.

Q What are the requirements when wheeling a simple panel?

A That the wheel tracks on each pass should at least run closely
alongside each other, if not in fact overlap and of a length terminating
close to the ends of the panel.

Q Is a No 1 die roll “too slow” when wheeling ordinary door panels or

turret roofs?

A No, granted adequate pressure, easier, smoother crowning results.

Q What is meant by the term “Ogee”?

A An “S” shaped curve, along the length of the panel.

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FITTING OF PLATEN WHEELS

a:aw:aw:wheeling 52
TO FIND THE TRUE SWEEP OF A GIVEN HEIGHT AND LENGTH

The points “D” and “E” are known and

a perpendicular divided into five
equal spaces is erected on ”E”.

The datum between “D” and “E” is

divided into five equal spaces
1-2-3-4.

From “D” straight lines are drawn to

5-6-7-8-9.

To establish a curve the intersection

of D-8 with 1, D-7 with 2, D-6 with 3,
D-5 with 4 and a curve laid in.

If the maximum height of the curve

above D-E is known, the
perpendicular should be four times
the known height.

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TO LAY A SWEEP, OR TEMPLATE, FOR A TURRET ROOF OR SIMILAR
PANEL

The datum between “A”: and “B” is

divided into eight equal parts as
shown. With centre “C”.

The verticals are then set up on the

datum. C-D is the maximum height
of the sweep required and A-d1 and
B-d are twice the height required.
The verticals A-d1, C-D and B-d are
divided into four equal parts. Join a-
a1-a2, b-b1-b2 etc.

The sweep is laid where the lines a2-

1, b2-2, c2-3, D, a1-6, b1-5, C1-4
intersect.

The datum “A” - “B” is the known

length and C-D the known height.

a:aw:aw:wheeling 54
TO FIND DIAMETER OF MATERIAL REQUIRED FOR A HEMISPHERICAL
BOWL

A-B being the diameter and C-D the depth.

The distance, the point D to the point B is equal to the radius of the material
required.

This also applies to E-F-D.

a:aw:aw:wheeling 55
TO LAY OUT A “RETURN” OR COMPOUND PANEL

Utilising No 2 method.

AB-BC is the total length of the

datum, FG the height (or depth) of
the concave curve and DE the height
of the convex curve. No dimensions
are given, these will be added or
marked as could be necessary.

Some “fairing” at point “B” could be

required.

a:aw:aw:wheeling 56
OVOID AN EGG SHAPED OVAL

First mark down long diameter A-B. Then point O obtained by making A-O
equal to half the width of the oval. Describe semi circle D-A-C with O as
centre.

Join B to D and make E-F equal to O-C by describing dotted curve and line
as shown.

Cut off B-P equal to D-E and so fix the point P for the centre of the end curve.

Join P to E and bisect the line P-E in H. Draw square to E-P, thus obtaining
the centre Q for the side curve. Join Q to P and produce to K.

The line Q-D will now be used as the radius for the side curve and P-B for the
end curve. Both curves meeting in K.

The object of putting in the line Q-K is, of course, to determine the meeting
place of the side and end curves.

If the construction is carefully carried out, there should be no doubt about the
curves meeting at K.

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