Vehicle Restoration Courses

Contour Academy provides three traditional sheet metalwork courses aimed at professional or amateur restorers of classic cars, motorcycles, 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 complex double-curvature sheet metalwork and will give you the confidence to tackle repair work and form and butt-weld panels.


It’s designed to suit all levels of experience and allows for varying degrees of competance.


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 elementary 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 - annealing aluminium alloy to aid shaping


Course costs

 

Four days - £1080 (£1296 inc. VAT)

 

2016 Stage 1 - Foundation Course dates

 

  • 7th - 10th November
  • 5th - 8th December

 

2017 Stage 1 - Foundation Course dates

 

  • 9th - 12th January
  • 13th - 16th February
  • 13th - 16th March
  • 24th - 27th April
  • 8th - 11th May
  • 12th - 15th June
  • 10th - 13th July
  • 7th - 10th August
  • 18th - 21st September
  • 9th - 12th October
  • 13th - 16th November
  • 11th - 14th December

 


All course dates



Stage 2 - Construction

This course covers the principles and practise of designing, making and use of patterns, 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, focusing on aluminium shaping and welding.


Course aims

To enable students to design, produce and use patterns, jigs and tooling to make and restore complex panels and structures and to shape and weld aluminium alloy.


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


Forming on tooling - Using bespoke tooling to replicate original detail


Flanging & wiring edges - forming flanges around tooling using advanced techniques


Shaping - forming and smoothing complex double-curvature aluminium alloy panels to accurately fit jig


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


Course costs


Four days – £1165 (£1398 inc. VAT)

 

2016 Stage 2 - Construction Course dates

  • 26th - 29th September
  • 14th - 17th November

 

2017 Stage 2 - Construction Course dates

  • 16th - 19th January
  • 20th - 23rd March
  • 15th - 18th May
  • 14th - 17th August
  • 20th - 23rd November

 


All course dates


Stage 3 - Own project

The course is designed to follow and build on techniques learnt on the Stage 1 and 2 courses, 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 you’ll 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 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


Course costs

Four days - £1500 (£1800 inc. VAT)


2017 Stage 3 - Own Project Course dates

  • 19th - 20th June
  • 16th - 19th October

All course dates