Building a Hand-Formed Aluminum Race Car Body from Scratch

In this episode, we cover the fundamentals of hammering out a low-crown panel and the techniques used to shape and refine it. We discuss why we chose to weld the panel together before it was fitting and flowing 100%, and the advantages of taking that approach at this stage of the build. We also dive deeper into the metal-shaping and fabrication processes that have brought the project to its current point, sharing the challenges, decisions, and lessons learned along the way. Whether you're new to panel fabrication or following the progress of the build, this episode offers a closer look at the methods and mindset behind the work. 0:00 Intro 1:06 Low Crown Panel 1:26 Preparing Aluminum 3:01 Power Hammer 6:00 Mistakes Made 7:08 Preparing to Weld 12:34 Tack Welds Go Wrong 17:00 Final Welding and Planishing