The Ferrari 250 gto

The aim of this assignment is to create a scale model of Ferrari 250 gto with an interdisciplinary team of 6 members. Prior to making model with aluminium sheets, a template was created using laser cut MDF pieces ‘waffled’ together.

Then we covered the template with masking tape to clearly visualise its curve and divide into several parts which then each one of us selected our portions. And we also made paper templates to accurately measure dimensions of each pieces and then cut aluminium sheet. My selected portion is the front wheel on the right side of the model. 

After cutting aluminium piece, I began hammering very gently along the line I marked initially for shrinking the metal sheet and create edges. for this process, nylon bossing mallet with sharp point was used.

Using another nylon mallet with round end, the edged were smoothened and stretched to make a curve for fender. And to bend it even further and make smoother and larger curve, it was hammered against a steel tube.

In order to depict the wheel, I decided to hammer on the outer surface which will give the engraving effect of the wheel. After calculating the radius of the wheel, it was then marked and clamped with wooden piece to elevate it from the table. I firstly hammered gently to push the area in and found a tool which had disc shaped metal on the end to add more sharpness.

Then using flat head hammer and metal dolly, I smoothened the surface and remove lumps.

Then on the spot where the headlight is, more curve was shaped through using round metal dolly.  Hammering with sharp end creates a dent which is later on stretched with mallets with round end. Also with the issue of the wheel constantly deforming the metal and I was also not able to create flat surface, hence I decided to cut the metal for more precision.

The other end of the metal could fit in English wheel which allowed easier smoothing process of its surface without additional hammering.

The edges are sharpened and refined for more sharpness and accuracy to the model so its identical to the template.

The front was the most challenging part of this process as the curve needed to be more stiff. So instead of using metal dollies since they have even curves, I used timber piece with slanted edge to shrink the front and hammered on sandbag or metal dolly to remove all the lumps.

images of completed portion after sanding and polishing.