It's one of the most common and yet challenging tasks in custom fabrication. Creating shapes and templates that fit and match the existing shape of the vehicle seems simple but it requires some forethought to do well. There are different degrees of fitment quality, and what separates mediocre fabricators from the superior craftsmen has to do with how factory something looks. Skilled fabricators are able to create panels and enclosures that fit so well that it's hard to tell where the factory part ends and the custom part begins. Super high-tech companies, like Five Axis Models (which specializes in creating modified or concept cars), are able to create perfect shapes based on the 3-D CAD files of the vehicle, but most of us (including even high-end car audio shops) are nowhere near as technologically advanced, nor do our projects justify such expense. This article shows a simple way to quickly create form-fitting templates that make creating pieces like trim panels and subwoofer enclosure bases easier and without breaking the bank.
Start by placing an appropriately sized piece of chipboard (available at most upholstery supply shops) next to the area to be templated. A common area that requires template work is the rear corner of the trunk or hatchback. While some shapes can be easily traced to create the complementary shape, the three-dimensional contours of some interior panels can present quite a challenge.
Tools such as the Multi-Scribe and Profile Transfer Wheel are simple, yet very effective tools that make creating complementary templates easy. Like many of the specialty installation tools and supplies in my toolbox, these can be found at www.mobilesolutions-usa.com.
Using the Multi-Scribe tool, trace a rough outline of the shape onto the chipboard. Keeping the tool straight, side-to-side, will help create a more accurate shape. Carefully cut along the line created by the Profile Transfer Wheel. Accuracy is very important during this step. The traced line will most likely be wavy and jagged, which is fine for this stage. Cut along the "general area" with a pair of heavy-duty scissors. At this point, the goal is to create a rough template that's within 1/2" to 1" of the desired shape. This step can be done quickly (a couple of minutes) without being overly concerned with accuracy.