Many thanks for posting your sequential fabrication photos. They could be used for teaching this rare art of hand metal forming.
As a metallurgical engineer, I am very keen to learn more about your skill and knowledge of metal working, particularly working aluminum.
Since you mentioned that you are doing this work "old school style" I am assuming that you first use a large ball-peen hammer to rough the initial flat sheet, then progressively use smaller hammers, then place the roughened part on a manual English-wheel to progressively roll it to shape. Is that right?
Or are you using a more modern hydraulic "iron-working" station with various tools to form-to-shape after the initial hammering?
If at all possible, a few photos of your equipment and tools would be great to see and learn from a true craftsman like you.
Thank you very much.
The process is exactly how you described it.
Rough hammering on a wooden stump, planishing with hammers and dolly's and ending on the English wheel. During 20+ years of car repair and metalshaping business, I gathered dozens of hammers, dolly's and various metalshaping tools. But I have a power hammer eckold type machine I made myself.
Old Italian masters called it Maglio.
In this job I used it only for making the inner part of the wheel well.
On large panels, a power hammer saves you a lot of time and effort.
But at the end each panel must be finished by hand.
If you have any more specific questions about metalshaping, I would gladly answer them.