If you remember back from part 4 of this build, we determined the profile of the tins with some cardboard cut outs. Its time to form this into metal!
The next step is to convert cardboard to welding wire. If you hold the cardboard over your bench top and hold a bright light behind it, you can cast a rough shadow onto your bench, which you can sketch around. I simply draw onto my metal bench top with a marker (which cleans off with acetone). Since I wanted to make the tanks 370mm long (to fit within the existing mounts you can see in the photo below), I simple drew two parallel lines on my bench 370mm apart, then moved the cardboard and light to scale the shadow to fit within my lines. No high tech required here.
Once you have a line on the flat surface, simple take the wire (I used 2.4mm TIG wire I had in stock, but any stiff wire would be fine) and carefully form it to the profile you want:
Repeat for the rear fender:
In the next installment, we’ll start building out the three-dimensional buck.
If you want to build your own bodywork like this and need help, I’m creating video courses covering this work in for my private members.