FEBRUARY 2014 ● www.popularmechanics.co.za 67

BENDME,SHAPEME

PM’s digital intern, Sarah Adams, was so bowled over by her encounter with authentic gearheads and classically curved fenders at last year’s Kalahari Desert SpeedWeek that she promptly decided to learn more – and signed up for a short course in sheet metal-shap-ing. Apparently it’s a girl thing, too…

When the opportunity arose to sign up for Barry Ashmole’s three-day

basic sheet metal-shaping course, I was apprehensive, to say the least. On the drive over to his picturesque farm in Stellenbosch, I felt as if I were about to attend my first day of school. I knew nothing about met-als or their idiosyncrasies and had no idea how to handle the oddly shaped tools that went with the territory. Against that, I was really excited about the opportunity of picking up a new skill.

My apprehension grew as I pulled into the driveway to a rousing welcome from a pack of dogs, barking wildly. They didn’t eat me, which was an excellent start. But, as I rounded the corner, it immediately became apparent that I had entered a paradise for gearheads. Anyone with any interest in cars, motorbikes or metal in general would drool over Barry’s impressive collection of old car bodies, motorbikes awaiting transformation, and tools galore.

If you are not a gearhead, this kind of thing is quite hard to explain. Whereas battered and rusty machines may not appeal to the aesthete, there’s something strangely compelling and satisfyingly poignant about their dents and scars… it’s the sort of lived-in look that distinguishes actor Tommy Lee Jones from pretty boys like that Twilight person, whose name escapes me.

(If you don’t believe me, ask PM’s editor, who recently spent a weekend in Prince Albert and was much impressed by the ruins of a Willys Overland wagon that his hosts had artfully arranged at the bottom of the garden.)

After being introduced to my course mates over a cup of coffee, we launched straight into the basics. And I was right – it did feel like being back in school, but in a good way. We seated ourselves in the enormous warehouse while Barry told us a little about himself, and how he got into the metal-shaping business. He explained some basic principles of metal-shaping, using illustrations on a blackboard. I was enthralled.

Armed with a modicum of knowledge

66 www.popularmechanics.co.za ● FEBRUARY 2014

68 www.popularmechanics.co.za ● FEBRUARY 2014

and a little more confidence, we were ready to start shaping some sheet metal. We be-gan with a primer on creating folds and flanges in metal sheeting. Then came the first glitch. Much as I hated to admit it, my woeful lack of experience in “manly” crafts and lack of physical strength worked against me: I had to abandon trying to work with steel, instead continuing my attempts with more malleable aluminium sheeting.

After learning the basics and testing our skills with small pieces, we gathered in a group to watch the master at work; naturally, he made it look easy. One of the main aims of the course is to gain an under-standing of the basic concepts and theory behind shaping metal, and to acknow-ledge that you need not rely on expensive machinery in order to do it well. Almost all of the exercises were completed using hand tools only.

After we’d had a chance to practise, it was time to make something of our choice. One of my course mates, Donovan, had brought in an old VW Beetle body that he was restoring, so we set about learn-ing how to measure, cut and shape the piece needed to replace a rusted part. While Donovan tackled that, I decided to go the arty route. No car parts for me; all I wanted to do was learn how to change the shape of something in metal. Much later, I walked away with (I thought) a very attractive wall ornament.

Barry also went into some detail about welding, angle-grinding, drilling and numerous other techniques that are needed when shaping and working with metal, and we all got a chance to use the appropriate tools. I especially enjoyed the welding… probably something to do with the fact that it didn’t require brute strength, and I could do it sitting down. Metal-shaping is tiring!

By the end of the first day, I was exhaust-ed, but also exhilarated. I was actually creating something, and it made me feel good. My artwork might not be accepted by the Museum of Modern Art, and for all I know, it might eventually be relegated to the ignominious role of bathroom soap-holder. But right now, it’s magnificent, because I made it. I’m proud of every elegant contour.

I walked in there with no idea of what to expect, and walked out able to say that I had learnt a great deal. I’d also had fun while doing it. My advice: give it a go.

Barry Ashmole’s sheet metal-shaping courses are arranged according to demand; e-mail barry.ashmole@gmail.com