I like this project because it makes the students read multiple sets of plans, use all their knowledge and skills from previous projects. Once the cycle ends, just release your foot pedal, reposition, and repeat. Obtain sheet metal. As a class we then go through and add in the dimensions we will need to know to make each part. Measure and mark your measurements for your tabs from each short edge. on Step 1, What is the use of hammer in the sheet metal tray, Answer You will get the most accurate measurements and marked lines if you work from the edge of your metal. Sheet Metal Box: This is a great project to make if you are new to working with sheet metal. My students enjoy making this tool tray and it is one of the projects that former students always come back and say they still have theirs from when they were in high school. Before you start constructing any project, you should have some semblance of a plan. When I completed that process the tape measure read just a shade under five inches, so I cut my metal to 4-15/16 inches. Bend your metal at the hem lines as far as your brake will allow. Use a scratch awl and try square to measure and mark the lines for your tray. I have a graph paper drawing in the pics below, but its not for this box) I am intrigued that you did not use a press brake to bend the sheet metal. Make straight bends and work through all the operations in this step in the correct order. I also included a blank set of plans for each part if you want to use your own measurements. To cut your metal to the correct size for your ends, use a measuring tape to measure the inside of your fully formed tray. Measure and mark your hem lines from the long edge of your metal. At this point in my class all of our sheet metal projects have been very simple with, at most, one bend. You'll want metal that's thick enough to make for a sturdy box, but thin enough to bend. That looks awesome, looks like something I would want for my home workshop. Question DONE! 5) after you finish bending all the sides up, use a spot welder to hold all the sides in place( you can also use rivets if you dont have a spot welder, but it takes longer) I wanted the top of my ends to just be wide enough to fit my handle. All of your bends will be made with your brake besides when you bend your tabs. Use your vise to fold your tabs down to 90 degrees. ( a flat version of your box. Scratch a line parallel to the edge you measured from through each of your tab measurement marks. I only give the students just enough metal to make all the parts of the tool tray, which forces them to plan out their entire process before starting. After your paint is dry your tool tray is finished and you can use it for whatever purpose you can come up with. 1 year ago I am assuming that you live in the US. ... Measure the height of the box. The size of the tray may change but the layout will basically be the same. Also, if the metal isn't clean enough you may not have a good enough connection for the spot welder to work. I hand out pre-made drawings for all of their parts without measurements. They also work great to hold small bolts and parts when I have to fix one of our machines in the shop. As always when you are painting or finishing a project be sure to be in a well ventilated area. In step 6 I use a hammer to flatten my hems. If you are new to simple sheet metal work and are looking for some more beginner projects to start with, check out my other sheet metal Instructables where I detail how to make DOG TAGS, VISE JAW COVERS, AND A SIMPLE BOX. Measure and mark your metal for your desired shape. When you start marking your angled lines try to get them exactly at 45 degrees. If those angled lines are not at 45 degrees when you bend, your tray your will either have unwanted overlap of metal or big gaps. Using wood screws attach one 2×4 on top. I use a foot shear for this step, its quicker and will leave my metal with a clean smooth edge, but you could do the same thing with a pair of aviation shears. I'm using my sheet metal brake to bend my hems in this Instructable. The layout for this step is pretty easy, just take your time and make sure when you cut you only cut away material that is not supposed to be there. Design and 3D Print Your Own Phone Case (in Fusion 360). Place your bent hems back under the teeth of your brake to press them down even further. My students always have trouble getting their hems flattened without dents and often times one of their sides gets bent at an angle. Again, use whatever method to attach your handle to your ends that you would like. Cut four strips of metal, each long enough to reach from the bottom to the top of the box, and wide enough to be bent in half and secured (usually about an inch or so on each side, so 2-3 inches total width). We have a finishing room in one of my workshops and that is where I painted my tool tray. Nice project, Im going to try it with my students. Position your electrodes over the area you want to weld, press down on your foot pedal until your electricity cycles through your electrodes. I took it out of the class this year to allow more time for other things since the common practice in manufacturing today is spot welding.
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