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How to Fabricate Sheet Metal for Car Restoration: A Comprehensive Guide

Car enthusiasts and DIY mechanics understand the importance of sheet metal fabrication in the process of car restoration. Whether you're working on a classic car or a modern vehicle, knowing how to fabricate sheet metal can save you time and money. In this blog post, we will provide a comprehensive guide on how to fabricate sheet metal for cars, including the tools and techniques you need to master.

Understanding Sheet Metal Fabrication

Sheet metal fabrication is the process of cutting, bending, and shaping metal sheets to create various parts and components for cars. This skill is essential for car restoration projects, as it allows you to repair or replace damaged body panels, create custom parts, or modify your vehicle's appearance.

Essential Tools for Sheet Metal Fabrication

Before you start fabricating sheet metal, you need to have the right tools at your disposal. Here are some of the essential tools you'll need:

1. Metal shears:These are used for cutting sheet metal and come in different types, such as manual, electric, or pneumatic.

2. Hammer and dolly set:This set is used for shaping and smoothing sheet metal. A hammer is used to strike the metal, while a dolly is held against the opposite side to provide support and help create the desired shape.

3. Body file:This is a flat, serrated file used to smooth out rough edges and imperfections on the sheet metal.

4. Sheet metal brake:This tool is used to bend sheet metal at precise angles. It comes in various sizes and capacities, depending on the thickness and type of metal you're working with.

5. English wheel:This tool is used to form compound curves in sheet metal, allowing you to create complex shapes and contours.

6. Welding equipment:A welder is necessary for joining sheet metal pieces together. Common types of welding used in sheet metal fabrication include MIG (metal inert gas) and TIG (tungsten inert gas) welding.

Sheet Metal Fabrication Techniques

Now that you have your tools, it's time to learn some sheet metal fabrication techniques. Here are some of the most common methods used in car restoration projects:


There are several ways to cut sheet metal, depending on the thickness and type of material. Metal shears are the most common method, but other cutting tools like plasma cutters, angle grinders, or even a hacksaw can be used. When cutting sheet metal, always ensure that you're wearing protective gear, such as gloves and safety goggles.


To bend sheet metal, you'll need a sheet metal brake or a bending tool. Mark the bend line on the metal using a straight edge and a permanent marker. Place the sheet metal in the brake, aligning the bend line with the brake's edge. Apply pressure to the metal, bending it to the desired angle.


Shaping sheet metal involves using a hammer and dolly set, as well as an English wheel, to create the desired contours and curves. Start by placing the sheet metal on a flat surface, with the dolly held against the underside of the metal. Use the hammer to strike the metal, working from the center outwards to create the desired shape.


Welding is the process of joining two pieces of sheet metal together. Before welding, ensure that the edges of the metal pieces are clean and free of rust, paint, or other contaminants. Clamp the pieces together, ensuring they are properly aligned. Use the welding equipment to create a weld bead along the seam, fusing the metal pieces together.

Tips for Successful Sheet Metal Fabrication

1. Practice makes perfect:Sheet metal fabrication is a skill that takes time and practice to master. Start with small projects and work your way up to more complex tasks as you gain experience and confidence.

2. Choose the right material:The type of sheet metal you use will depend on the specific car restoration project. Research the appropriate material for your project and ensure that it's suitable for the intended purpose.

3. Measure twice, cut once:Always double-check your measurements before cutting or bending sheet metal. Mistakes can be costly and time-consuming to fix.

4. Be patient and take your time:Sheet metal fabrication can be a slow and meticulous process. Don't rush, and be prepared to spend time refining your work to achieve the best results.

5. Safety first:Always wear appropriate protective gear when working with sheet metal, including gloves, safety goggles, and ear protection. Additionally, ensure that your workspace is well-ventilated, especially when welding.

With these tips and techniques, you'll be well on your way to mastering sheet metal fabrication for car restoration projects. Whether you're repairing a damaged body panel or creating custom parts for your vehicle, this skill is invaluable for any car enthusiast or DIY mechanic. Happy fabricating!

how to fabricate sheet metal on cars

What is Sheet Metal Fabrication

Sheet Metal Fabrication is the process of forming metal sheets into structures or parts using various techniques such as cutting, bending, and welding.

This process commonly use for products such as car parts, building materials, and household appliances.

The sheet metal is often cut to size and holes using a shearing machine or laser cutter, and then bent into shape. Once the parts formed, they are typically welded, riveted, or fastened together to create the final product.

Sheet Metal Fabrication Service

Asianstar Professional Sheet Metal Fabrication

Sheet Metal Fabrication Service

Asianstar Company Sheet Metal Fabrication provides a range of services to clients.

We have machines involves Cutting, Bending, Punching, Drilling, Welding and Forming, we also have hand-tool to make samples of sheet metal fabrication samples in rapid reaction.

With our skillful engineers and tools, we are able to provide complicated structure sheet metal components, and then apply surface finishing treatment on components and support clients to assemble the final products.

For huge quantities sheet metal fabrication demands, we use our own CNC Machines to open tooling or mold for sheet parts, with our in-house facilities supporting, we can carry perfect result on the structure and productivity.

Asianstar: Professional CNC Machining Supplier

From year of 2005, Asianstar Company establish the CNC Machining Factory in Guangdong Province, China.
We mostly provide CNC Turning, Milling, Drilling, Grinding, and Multi Machining processes service on various materials.
With the Belief of becoming a key supplier in the supply-chain of Precision Components, we strictly control our product quality, keep high precision on our components production, buildup the whole-process QC System and submit the satisfaction for every order.
By long term development, we have buildup partnership with world-wide clients, supporting our partners in Designing, Optimizing, Producing and Testing on each type of components.


Multiple Machining Processes

Multiple Machining Processes

Asianstar has various machining processes to support different types of components from client, we can choose the best suitable manufacturing solution to carry result in perfect performance and cheap cost

Flexible Custom Service

Flexible Custom Service

With skillful machining technologies, Asianstar is flexible to support clients on different materials and different structures of the components, we also flexible on the components quantities and even assembly

Create Designing for Clients

Create Designing for Clients

Not only producing according to clients drawings, Asianstar also propose the better designing to clients, supporting clients to buildup improved designing or even new generation components

Standard Procedures

Standard Procedures

Asianstar production, as experienced by many years, is strictly following internal Standard Operating Procedures, to make sure the production schedule is smooth and plans are well carried out well without accidents

Standard Procedures

Standard Procedures

Asianstar strictly controlling product quality by system. We start QC controlling from production plan once setting up, to production process by monitoring QC checking and until the final Inspection before packing

Fast Lead-Time Delivery

Fast Lead-Time Delivery

Asianstar strictly control the production processes, teams keep the plan moving ahead according to the procedures, we have internal time management schedule which mostly bring earlier lead-time of delivery


CNC Turning Service

CNC Turning Service

Our CNC Turning Service provides different sizes of roll shape work-pieces, the diameter range is from 0.5mm to 480mm, reaching tolerance +/-0.003mm.

CNC Milling Service

CNC Milling Service

Our milling machines and CNC centers are able to produce complicated structure part, five-axis devices produce multi-sides at one-time jag which bring high precision result

Sheet Metal Fabrication

Sheet Metal Fabrication

Our Sheet Metal Fabrication provides slicing, punching, bending, welding, painting and assembling for set products, unique tooling for each project to raise production efficiency

Aluminum Extrusion

Aluminum Extrusion

Our Aluminum Extrusion brings clients various shapes of aluminum parts, high efficiency for mass quantity, our precision extrusion mold control tolerance within 0.01mm

Forging Service

Forging Service

For some steel serious products, we apply Forging Service to make out their outer shape and them use CNC devices to start drilling, forming, rolling, cutting, etc.

Finishing Service

Finishing Service

Our Surface Finishing Service uses chemical or electro post-treatments after machining tasks are finished, normally includes Oxide, Anodizing, Passivation, E-Plating, Painting,etc.


  • Q1.Do you support ODM/OEM?

    Yes, we support ODM/OEM, we provide custom-made service for clients or even support clients on designing or improving

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