BEIL0014_The Blister

Equipment:
Aluminum Sheet	Guillotine
Wood Jigs	Metal Clamps
Round Nylon Headed Mallet	Corking tools (different shapes)
Bolts and Nuts	CNC Router
MDF	Drill

Step one:

Creating the template to sandwich the metal sheet, by using the CNC router. And drill four holes on close to the corners of the template.

Step two:

Cut metal sheet into the size suit for the template. Then place the sheets between the wood jig and clamp the figs together tightly by bolts and nuts. And clamps whole set up on the benchtop by metal clamps.

Step three:

Striking the metal sheet. Start from the edge, using corking tools, where round headed mallet cannot reach.

Step four:

Hammer slowly close to the center. The closer to the center, larger hammer should be used, to avoid less hammer mark. Hammer the sheet follow the shape of the template. Slowly and patiently.

Step five:

Check the depth. I wanted to create a blister with a depth slightly deeper than the thickness of template. If not deep enough go back to step three.

third check, still not deep enough

Perfect!

Step six:

When the depth close to the thickness of the template. Place anther jig beneath the setup to prevent hit the metal sheet on the rough bench-top. The reason I choose this template is the narrow tail, I think this will increase the difficulty. its hard to create much depth and keep smooth at this part. 

Thank you for your sacrifice.

The depth is not enough close to the end of the tail, and shape is bad as well.

Step seven:

Take out the metal sheet and check if the surface is smooth, and if the edge is crispy can sharp. If not smooth go back to step three or four. if the edge is nor clear enough, you can hammer the sheet without the top jig, but remember to keep an eye on the flatness of the unstriked part of the sheet. 

Still need further planishing.

Final Product: