How to Make Domes Out of Aluminum

Producing aluminum domes can be dangerous for your fingertips, wear work gloves.

Aluminum domes can be used for a number of decorative purposes, but making them so that they are relatively even can be something of a challenge. This is because not only do you have to bend the metal you are forming into a dome, but you also have to stretch it so that it does not bend along a line. You have two choices of tools you can use to accomplish this task. An English wheel will form a gradual dome shape and a planishing hammer will produce a much tighter, smaller dome.

Things You'll Need

• English wheel
• Planishing hammer

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Instructions

English Wheel

1. Position the aluminum sheet you will be forming into a dome between the steel rollers of the English wheel.

2. Move the aluminum sheet back and forth so that it rolls between the English wheel's dies. You will begin to notice the metal taking on a curved shape. As it does this, turn the sheet counterclockwise while you continue moving the sheet back and forth.

3. Roll the aluminum sheet while turning it in a counterclockwise direction until it has reached your desired dome depth. You won't be able to get the curvature too tight with an English wheel; they are meant to build sweeping curves.

Planishing Hammer

1. Position the aluminum sheet between the hammer and the die of the planishing hammer. In this process, you can use an aluminum sheet that was previously formed with an English wheel, but you cannot form a planished dome with an English wheel. The curves produced are too tight.

2. Activate the planishing hammer and move the sheet continuously as the dome forms. Hold onto the edges of the sheet to help prevent your fingers from becoming caught in the hammer. The dome will form more quickly the harder you press the activation pedal of the planishing hammer. To work more slowly, release the pedal slightly.

3. Insert a finishing hammer die into the planishing hammer head. A finishing die smooths out the ridges and deformities formed by the planishing process. You don't have to use the finishing die, however, if you like the way the dome looks with the ridges.

Tips & Warnings

• Wear leather gloves whenever working with these tools to prevent injuries to the fingertips.

References

• "Sheet Metal Handbook: How to Form and Shape Sheet Metal for Competition, Custom and Restoration Use"; Ron Fournier; 1989