Vehicle Restoration Courses

Contour Academy provides three traditional sheet metalwork courses aimed at

professional or amateur restorers of classic cars, vintage aircraft enthusiasts,
customisers, kit and special car builders.

The techniques involved are relevant to vehicle metalwork where complex shapes and
structures need to be reproduced or restored.

The courses Stage 1, Stage 2 and Stage 3 - deal with all levels of competence, from
complete beginner to the experienced professional. We teach students how to work with
basic hand tools through to specialist machinery some of which we have developed
ourselves.

The courses are run with the individual in mind allowing time to ask questions particular
to your needs. We limit the number of pupils so that you are given a significant amount
of one-to-one tuition.

The Courses
Stage 1 - Foundation
This course is an introduction to the principles of sheet metalwork and will give you the
confidence to tackle repair work and form double-curvature panels.

Its designed to suit all levels of experience and allows for varying degrees of skill.

During the course we will demonstrate how to manufacture professionally-finished

panels with basic tools and equipment as well as using more sophisticated equipment
such as wheeling machines. There is time available to discuss your own projects.

Course aims
To enable students to produce double-curvatures panels and alter and fit obtainable
panels.

You will learn

Pattern making - measuring and marking out complex shapes and structures
accurately

Jig building - constructing basic jigs and fixtures to aid reproduction of original
parts

Body construction - aligning panels to create flowing bodylines and parallel gaps

Tool making - how to construct simple tooling to replicate original recesses etc

You will learn and practise

Flanging - shrinking and stretching metal to form convex and concave curved
flange. You will also learn how to wire a flanged edge

Shaping - hand forming and smoothing double-curvature panels to accurately fit

a jig and hammering smooth over a steel dolly. We will also teach you basic use of
the wheeling machine

Butt welding - joining thin sheets of metal using a tig welder without adding
filler rod to create a smooth finish. This is an important technique used in the
making and fitting of repair panels to achieve a seamless joint

Annealing and heat shrinking - annealing aluminium alloy to aid shaping and
heat-shrinking steel panels to repair stretched areas

2014 Stage 1 - Foundation Course dates

Two day

3rd - 4th March

20th - 21st October

Four day

13th - 16th January

17th - 20th March

12th - 15th May

7th - 10th July

15th - 18th September

10th - 13th November

You can book online today and also arrange your accommodation from as little as 30 a
night in our on-site self-catering cottage.

Stage 2 - Construction
This course covers the principles and practise of designing, making and use of jigs and
tooling for the manufacture and restoration of complex sheet metal panels.

The course is designed to follow and build on the principles established during the
Foundation course.

Course aims
To enable students to design, produce and use jigs and tooling to make and restore
complex panels and structures.

You will learn

Developing jigs - purpose, design, construction and use

Developing tools - purpose, design, construction and use

Materials - understanding the properties and appropriate use of various

materials

Joining materials - exploring the various methods of joining panels

You will learn and practise

Taking profiles - replicating complex curves and configurations

Making patterns - developing patterns to accurately reproduce original parts

Constructing jigs - making, setting out and assembling jig structure

Making tooling - producing bespoke tooling to replicate original detail

Flanging - forming flanges around tooling using advanced techniques

Shaping - forming and smoothing complex double-curvature panels to accurately

fit jig

Butt welding - using a TIG welder to join thin sheet steel and aluminium alloys
without filler rod enabling a joint to be hammered to a smooth finish

Stage 3 - Own project

The course is designed to follow and build on from the Construction course putting into
practise the principles established to make or restore complex sheet metal panels and
structures.

Students are encouraged to bring along their own project to work on under expert
supervision.

Course aims
To enable students to produce and restore complex panels and structures.

You will learn and practise

Making panels - forming complex panels and structures

Repairing panels - analysing corroded and damaged parts. In addition youll

learn what to replace, how to remove rusted areas and where best to position
welded joints

Welding - practising the various forms of welding used on panels; MIG, TIG, Oxy
Acetylene and resistance spot

Flanging - forming flanges around tooling using advanced techniques

Shaping - forming and smoothing complex double-curvature panels to accurately

fit jig

Butt welding using a TIG welder to join thin sheet steel and aluminium alloys
without filler rod enabling a joint to be hammered to a smooth finish

Finishing - lead loading, use of abrasives, power tools and hand finishing