Sheetmetal cutting

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I need some help cutting sheetmetal. What is the best method for cutting nice radius's and angles? I am working on making a firewall for my mustang, but I dont have experience with sheetmetal like this. I tried the top half but it doesnt fit how I would like it to. Does anyone have any ideas on laying this out or making a template? The 45's (or close to 45) degree angles make everything really complicated. Attached ImagesHTP Invertig 201Lincoln Idealarc SP250Miller 180 AC StickBy farmall:They should have held the seagull closer to the work, squeezing evenly for best deposition.
Reply:I find the best thing for making templates is bristol board, cheap, easy to cut, stiff enough to keep it's shape and if you do screw up you can repair it with a piece of masking tape and some scraps. Tape a couple of pieces together so it's bigger than the opening and tape it over the hole and roughly mark it from the inside or if it's easier go the other way 'round.As for cutting it to shape it depens on what you have available, nibblers, jig saw with a fine metal blade, zip cut followed by a flat wheel to smooth out the edges.....Mike
Reply:X2 of the bristol board or chip board for the template. Difficult areas can be done in sections and then just tape them together for final fit..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Ok guys good call on the board. I dont have a nibbler or a jigsaw. Which would you all reccomend for this? I have most of the tools for "heavy" cutting and grinding, this is a bit 'delicate' for me HTP Invertig 201Lincoln Idealarc SP250Miller 180 AC StickBy farmall:They should have held the seagull closer to the work, squeezing evenly for best deposition.
Reply:I have a small hand nibbler I picked up years ago. I want to say I got it thru Eastwoods, but it's been too long. Does up to 18ga steel. I use it all the time for duct work.http://www.eastwood.com/supercoup-nr...er-shears.htmlFind someone with a small plasma and give him a few bucks to cut it out.Finishing and grinding, a small die grinder or dremel with carbide cutter does a nice job, just be careful..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Zipcut and a grinder for cutting and a flapwheel for finishing.....Mike
Reply:What about your plasma? if you can turn it down low enough and possibly make a guide for it that should do it without too much trouble.Ryan_______________________OF COURSE I DON'T LOOK BUSY... I DID IT RIGHT THE FIRST TIME
Reply:You should use a portable electric metal shear.  Makes smooth straight cuts and curve cuts in sheet metal."The reason we are here is that we are not all there"SA 200Idealarc TM 300 300MM 200MM 25130a SpoolgunPrecision Tig 375Invertec V350 ProSC-32 CS 12 Wire FeederOxweld/Purox O/AArcAirHypertherm Powermax 85LN25
Reply:I have been using my plasma and it isnt bad, just doesnt seem like the "proper" tool for fitting sheetmetal. On all the race cars I see they have some superb sheet metal work, very clean radius cuts around the tubing, just trying to make some nice looking sheet metal for my car.HTP Invertig 201Lincoln Idealarc SP250Miller 180 AC StickBy farmall:They should have held the seagull closer to the work, squeezing evenly for best deposition.