DIY Automotive Sheet Metal Fabrication | 5 Minute Guide

Make your own professional-quality parts using basic shop tools and materials.

While the use of a cheap CNC router and a 3D printer speed up the process, you can create parts that rival factory quality at a fraction of the cost even without access to those specific items if you don't mind spending a bit of time on the end of a hammer.

The process uses inexpensive fiberboard (MDF) to create press tools instead of costly steel dies or 3rd party manufacturers. Traditional hammer forming techniques shape the metal, while simple 3D printed jigs handle precision cuts for brake caliper clearance, although if you don't already have everything modelled in CAD like this project you could also simply measure it out manually.

This approach gives you complete control over your parts without waiting for quotes, minimum orders, or expensive tooling costs. Perfect for one-off builds, restoration projects, or anyone who wants some DIY independence and satisfaction for their own custom automotive fabrication.

0:00 – Custom Brake Shield
0:22 – CNC Tool Path Setup
1:22 – Cutting MDF Press Tool
1:35 – Pressing Brake Shield
2:15 – Hammer Forming Lip
2:47 – Heavy Hammer Shaping
3:25 – Trimming Excess
3:43 – Edge Cleanup
4:01 – Test Fit On Truck
4:20 – 3D Print Caliper Jig
4:44 – Jig Test Fit
5:01 – Cutting Caliper Clearance
5:12 – Deburr & Final Fit
5:20 – Duplicating & Coating
5:23 – Outro