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 After making an accurate template...  After making an accurate template from poster board, Shoaf transfers the shape to a piece of 18-gauge steel. At first glance this may not look like the filler piece, but with some bending it will fill the void.  From the outside the gap is...  From the outside the gap is apparent. Note that the fender “drops off” toward the front of the car. The new headlight ring panel will eliminate most of that radius. By leaving the fender intact the headlight positioning was guaranteed to be in the factory location and the mounting of the headlight bucket also employed the original mounting flange.  Using an open-throat rotary...  Using an open-throat rotary shear is the easiest way to cut contour lines in sheetmetal. Working carefully the pattern is cut out, leaving no distortion on the cut panel. These shears are available from sources like Woodward Fab.  Here is the finished product...  Here is the finished product for the passenger side of the car. This piece will fit the new Olds headlight ring and provide the transition to the stock ’51 Ford fender.  When it comes time to shape...  When it comes time to shape the piece it can be done right on the fender. First find a center line on the new panel that matches the centerline on the Olds headlight ring and the top of the fender. Align those marks and begin contouring the metal by gently pushing down around the fender.  You may have to move the panel...  You may have to move the panel on the fender a bit to get the contours correct, bend slowly, test-fit, and then bend some more. Note the index marks on the panel that align the new piece with the center of the fender and the center of the headlight ring.  On the inside of the fender...  On the inside of the fender the bends become a bit more difficult as the metal must wrap around the ring and also have a slight flare to make a clean radius where it blends into the fender. Once again, bend, test-fit, bend, and test-fit.  As we mentioned earlier the...  As we mentioned earlier the headlight was moved back into the fender 1 inch to eliminate any bug-eye look to our installation. The new sheetmetal filler panels placed the headlight ring in the proper position; we had to mount the headlight bucket rearward the same amount. After breaking a 90-degree angle on a piece of 18-gauge steel, a shrinker develops the radius.  Shoaf continues the shrinking...  Shoaf continues the shrinking process until he has a diameter equal to the original ’51 Ford headlight bucket. Keep the headlight bucket nearby and check the diameter as you shrink.
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