Tyrrell Coachworks now based in Wexford, have over 100yrs expertise in the auto body industry going back to the early 1920s when our grandfather Tom O’Brien worked in some of the earliest bodyshops in Dublin.

Today we specialise in fabricating panelwork for rare classic and vintage vehicles for the Irish, UK and European markets using a selection materials including steel, aluminium, copper and brass.

Below is a brief overview of the tools and techniques involved in the metal fabrication process.

The Art Of Metal Shaping

Coachwork is a term used to describe the body of a horse drawn carriage, and when the horse was replaced by the internal combustion engine coach builders quickly adapted their skills to what would be the greatest innovation in transport since the invention of the wheel.

Whilst the bodywork of vehicles has evolved over the last 120 years, the art of metal shaping has remained virtually unchanged. This 1905 Daimler is a perfect example of coach building with its new ‘Roi des Belges’ body including ash frame, designed and built by Tyrrell Coachworks in 2018.

The Devil Is In The Detail

The quality of the finished panel will be determined by the time taken to produce a high quality pattern. All of the panel work in these pictures started out as a paper pattern which was then transferred on to a metal blank which is used as a template to create the finished panel. Whilst paper patterns can give the overall shape and dimensions of most panels (ie. wing, bonnet) it will require some three-dimensional help.

A buck is the internal shape of the panel to be fabricated and can be made of steel, timber, fibreglass or a combination of all three. The new panel when finished should replicate the dimensions laid out by the buck exactly and will be an invaluable asset if multiples of the same panel are to be produced.

The Tools Of The Trade

With the exception of one or two machines most of the fabrication is carried out using the same traditional hand tools and machines that were in use over a 100yrs ago, for example the wheeling machine and flypress.

Some new panels will require tooling to be custom made to fabricate the panel. This 1902 Peugeot Type 48 bonnet with brass inlay is a perfect example of this type of work. The descending style of louvres on this bonnet required that each of the 24 louvres needed its own custom made die.

The wheeling machine is one of the simplest machines ever invented but is capable of creating the most complex shapes imaginable. This new bonnet for a 1968 Jenson FF was produced in one piece using the wheeling machine.