Get Started Fabricating Sheet Metal with the English Wheel

In the early days of the auto industry, each vehicle’s bodywork was often a one-of-a-kind creation. Before mass-production stamping became the norm, body panels were individually handcrafted by skilled coachbuilders. And one tool allowed them to shape sheet metal into complex curves and contours: the English wheel.

Handmade bodywork is no longer a reality in modern vehicle manufacturing, even at the highest end of the market. However, the English wheel still serves as a critical tool for many restorers and custom fabricators. Its versatility creates complex surface, from sweeping fenders to elegant compound curves that simply can’t be created on other machines. For a novice metal worker, the English wheel can seem like a daunting piece of equipment. Success comes from developing an intuitive feel for the work that only comes with practice. Getting started, however, is as easy grabbing some sheet metal and just running it between the wheels.

How an English Wheel Works

An English wheel consists of a pair of steel wheels mounted on a sturdy frame with a gap between them. A large, flat-profile wheel is typically mounted in a fixed position to the top of the frame. Below it sits a smaller adjustable wheel with a slightly convex profile, often called an anvil or a lower wheel.

The operator adjusts the gap between the wheels according to the desired curvature and thickness of the metal. The operator then moves the metal sheet through the English wheel while applying pressure. By rolling the sheet back and forth between the wheels, the metal gradually forms into the desired shape. Multiple passes with gradual adjustments to pressure and wheel gap eventually result in the proper curvature.

Getting Started

• Start with a simple project in mind. Knowing what your final product will be allows you to work towards a definitive goal. Making a sunroof filler panel, like we’re doing here, is great way to begin. It has defined dimensions and the original roof provides good visual reference for shaping the metal.
  
  Begin by practicing with gently curved surfaces. This allows you to familiarize yourself with the operation of the English wheel, develop your technique, and gain confidence before tackling more complex shapes. Again, the sunroof filler panel is perfect for a beginner.
  
  
• Focus on your technique, including controlling the pressure applied to the metal, maintaining even passes through the wheels, and controlling the direction of movement. Pay attention to how the metal responds to different adjustments and movements to achieve the desired curvature.
  
  
• Experiment with a variety of metal materials, such as aluminum, steel, or copper. You’ll soon understand how each material behaves and responds differently to shaping. This can help you develop a better intuition for their characteristics and how to work with them effectively.
  
  
• Practice patience and persistence as you work. It may take time to develop the technique and feel needed to produce the results you want. Be prepared to make mistakes and learn from them as you progress.
  
  
• Take advantage of resources like books, community forums, and online video channels to learn more about metal shaping techniques. Consider attending workshops or classes taught by experienced metalworkers to receive hands-on instruction and guidance.

The English wheel has long been a cornerstone of automotive coachbuilding. In the hands of a skilled craftsmen, it’s still the most versatile tool to transform raw sheet metal into beautiful, original bodywork. You can master it too; you just have to take the first step.