I have decided to make a new tailgate from scratch. I can't use this rare factory one as is anyway, because it is the wrong size for my custom bed, so would end up only using the WO logo, (Willys Overland), from the middle. Better to sell this to a restorer for their build.
It is easy enough to just bead roll or emboss the logo as others have done if the letter width is kept the same as well as the height. But I want to have a go at following the factory style for the W which is the hardest part of this logo. Having the original there next to me has made making this layout easier. I am also reducing the overall size and width of the letters by 10% to suit my tailgate.
The letters are not a round bead but a V shape. I achieved that by using my tipping die on the bottom rather than the round matching profile. It gave exactly what I was after. I started with the O first as the W ends up in the foreground if done after. Rather than stopping and starting, I thought it would be easier to get continuity if I ran around several times without stopping until I got the height needed.
I shaped an old cold chisel to match the shape I wanted for the ends of the bends where the W passes through the O.
Used another flat faced punch to knock down the space in between the beads.
Now as the W changes in width, I cannot use the same setup as the O. So I am following the outline of the W while pulling up with the sheet to create the fold. This is slow work that has to be accurate every single pass.
I then flipped over the sheet and pressed the tipping die into one of my old road racing roller skate wheels. It has a soft durometer to allow the metal to push into the middle of the letter. The process was repeated back and forth a dozen times.
When I saw no more change in height of the W on the bead roller, I switched to stretching the metal by hand to get it up to the factory height. Just using the wedged end of a hammer as a chaser by moving it along the letter while hitting it with the brass mallet. I raided the recycled tyre paver from the cat run which worked great for this!
https://www.clarkrubber.com.au/.../3...nvironmentally... Stretching the areas between the letters to flatten everything out was done directly on the bench without the mat.
Also planished it by having the letter over the edge of this stake and carefully hitting with a small hammer on the outside.
The results of 3 afternoons work during our fifth lockdown was worth it. I learnt more of what can be accomplished with the tools I have. I think that it is a good facsimile of the factory pressing and I can go on with making the rest of the tailgate which will have a custom design to suit my build.
