Month after month we feature bikes that simply blow us away with the detail in their sheetmetal. Curves, angles, and shapes that we couldn't even draw -- let alone bend metal into -- seem to get taken to the next level with each new bike we see. We knew these interesting designs were hand-formed and we understood the basics of how metal is shaped, but to be honest, we had no idea what all the actual steps -- from beginning to end -- were.
As luck would have it, Ron Covelle, one of the best metalworkers in the business was doing a steel fender-building workshop at Jim Nasi's new shop in Phoenix, so we signed up instantly.
Prior to the class starting one Saturday morning, we wandered around talking to the 20-some attendees to find out why they were there and where they came from. It came as quite a surprise to find people from all over the country -- some had traveled from as far away as Chicago and Florida -- in attendance. Then, to further our surprise, we found that more than half the class either worked in a bike shop or body shop and had a decent amount of metal-bending experience. The others fell more into our category: those who needed to learn everything.
Covelle runs his class very loosely, emphasizing comfort and encouraging questions. The day flew by, and while we learned a little more than our aging gray matter could comprehend in a single day, we left feeling like the rest of the class: We wanted to sign up for the next workshop.
To get more information on Covelle's classes or to get the schedule for this year, call (800) 747-4631.
1: Covelle starts all his...
1: Covelle starts all his classes the same way: talking about how he got started in metalwork doing aluminum dragster bodies in the late '60s.
2: Nasi's shop was the perfect...
2: Nasi's shop was the perfect setting for the workshop, with plenty of space and a bay full of in-progress custom bikes to look at.
3: We were going to see an...
3: We were going to see an Indian-style fender built. Ron showed up with the sides cut out ahead of time, figuring that watching him cut a shape from the 19-gauge sheetmetal would bore us.
4: While 19-gauge is fairly...
4: While 19-gauge is fairly strong, it's still pretty flexible. Covelle explained that by adding a slight dome or curve to it, the strength would increase. With that thought floating around the room, he gave the flat panel a trip through the English Wheel.
5: As you can see, just one...
5: As you can see, just one full pass (for each part of the panel) already added quite a bit of curvature to the piece.
6: Just to add some style...
6: Just to add some style and dimension to the panels, Covelle ran them through a bead roller.
7: As you can see, the result...
7: As you can see, the result is pretty cool.
8: Now it was time to add...
8: Now it was time to add some more curvature to the flat panel. Using a shrinking jaw, he went around the whole panel to ensure uniformity.
9: This comparison shot gives...
9: This comparison shot gives you a better idea of the results of the shrinking process.
10: Then it got loud. Ron...
10: Then it got loud. Ron got out a post dolly and a hammer and started to add enough shape to let the side panels blend into the top piece he would make to join them together.
11: Then, to add a lot more...
11: Then, to add a lot more strength to the side panel Covelle used a handmade tool to bend a hem into the edge. He started by notching the ends and then slowly, patiently ran the bender from one end to another. This procedure exemplifies metalwork: slow and patient. Take your time to get it right instead of fixing a mistake. Once the hem gets past 90 degrees, he used a hammer and dolly to bend it flat.
12: Here is a finished fender...
12: Here is a finished fender panel. Obviously, Covelle had to do another panel before we could move on.
13: A pre-cut piece of metal...
13: A pre-cut piece of metal was roughly bent to the panel to ensure proper size...
14: ...and sent straight to...
14: ...and sent straight to the English Wheel for some shaping.
15: Not satisfied with the...
15: Not satisfied with the slow going that the wheel was giving him, Covelle got out a mallet and sandbag and beat on the fender...
16: ...until it looked like...
16: ...until it looked like a bag of walnuts. Now it has enough shape in it to shrink the edges in preparation for joining it to the side panels.
17: Then the walnut-shaped...
17: Then the walnut-shaped dents were smoothed out on the wheel.
18: There is a lot to explain...
18: There is a lot to explain in this photo. Covelle started by making an alignment mark on the fender and the centerpiece. With the position confirmed, he slid a straightedge in to support the panel and got his TIG welder ready. Ron likes to do fusion welds when tacking things together instead of using any filler material. This ensures a better fit overall.
19: Fast-forward past a lot...
19: Fast-forward past a lot of tack-welding and you basically have an assembled fender. Ron took a minute to ensure everything was to his liking and to assess where he would trim the edges.
20: Covelle marked the shape...
20: Covelle marked the shape he wanted with tape and then resorts to basic metal shears to trim the fender edge. Once it was cut, he folded a hem into it just like he did on the side of the panel.
21: With everything tacked...
21: With everything tacked together, it was time to drop the welder's hood in place and lay down a continuos bead of material.
22: Using a slap hammer, Covelle...
22: Using a slap hammer, Covelle set out to smooth the minor imperfections in the welded areas.
23: Cool tools always justify...
23: Cool tools always justify a picture or two. In this shot, Ron pulls out his bull's-eye pick to get to a few hard-to-reach spots. Essentially, the pick has a flat end (similar to a dolly) and a pick (simulates a hammer), and you squeeze the handle to slap them together and work out a dent or imperfection.
24: Starting with a hand file,...
24: Starting with a hand file, Covelle started to metal prep the welded area...
25: ...then moved on to an...
25: ...then moved on to an air-powered grinder.
26: At the end of each class,...
26: At the end of each class, Covelle does a drawing for the part made during the class. The winner of this fender happened to be Kyle Krejci, owner of Independent Gas Tank Company. See, everyone can learn something.