[theastronaut]

Making the front inner rocker. Laid out the pattern on sheetmetal.






Pre-stretched the bead rolled area in the english wheel using the smallest diameter wheel. The beads will "pull" metal inward causing the metal to distort around the beads so this combats that from the start. Much easier to pre-stretch than it is to try to get the distortion out later.






Half round beads added. You can see that the area around the bead is flat.




After rolling the raised area using offset dies in the bead roller. Some distortion but it's minimal and easy to work out.




After about 5 minutes with a rubber mallet to flatten the panel.






The front corner was a little sharp so I used the tip of a screw driver and tapped it a little rounder. Then ground out the marks and smoothed it with a DA sander. Not really necessary on an inner rocker that no one will ever see...






After bending the top edge 90* and washing with PPG DX.