Sheet Metal Box
Dimensions
The Sheet Metal Box will be made with one piece of 6ā x 8ā aluminum sheet metal
Dimensions of the Box:
Bottom 6" x 3"
Side 4" x 1.5" x2
Lid 4" x 3.5"
Mark the cut lines and the bend lines on the 6" x 8" sheet of Aluminum using a fine tip sharpie or Stabilo marking pencils
*Stabilo pencils use a very soft lead if you use the same force as a regular lead pencil they will break!*
Step 1:
Find a sheet and measure to ensure it is the proper length and height
This piece is slightly too long so it needs to be cut to size
*Cutting your piece to size can be done after all dimensions are marked*
Step 2:
From here, continue to mark the dimensions onto the metal. Reference the layout above as all parts of the box should fit within the 6" x 8" space measured
Use dotted lines to differentiate the bend lines from the cut lines so you don't accidentally cut them!
Cutting
Reference layout before cutting, you will need to cut parts out in a specific order
*Lid is not pictured*
Bending
Use the extra parts cut out from the sheet of 6" x 8" Aluminum and mark bend lines to practice making 90 degree bends before using parts for your box
Bending bottom of box
Move the handle down slightly, this will act as a clamp to secure the material in place.
*If you move the handle down too much it will start to bend*
Look to the side of the machine to see the degree of the bend
Bending Sides
Before bending the sides of the box, measure the inside distance between the walls of the bottom of the box
If the measurements differ, adjust the markings for the bends on each edge, for the sides
Line up the side and the bottom like the picture to the right.
Align bend to inside edge of bottom like show
Bend on line
Repeat Step 1& 2 once you've made first bend on a side panel
What happens when sides are a bit too short
Well fitting sides
The sides of the edges should fold inside and create a snug fit. Two likely outcomes can happen if your measurements are off
The sides will be too long overlapping the edges
The sides will be too short and there will be gaps
Making Holes
To hold the bottom and sides of the box together we will use rivets
For some information about rivets and how they work click here!
Before we can rivet the two pieces of metal together we have to create a hole in both pieces first so the rivet can fit through the material
For this process you will be using a hole punch to create holes for the rivets
Verify with a staff member that the smallest size (3/32") is in the hole punch.
Step 1
Clamp one side, you may need to use tape or small clips as well.
Step 2
Punch the first hole in the bottom corner.
Align the hole punch in as close to the corner as can fit and squeeze on the handles to punch a hole.
Step 3
Rivet the first hole before punching any other holes! If you punch again before putting in the rivet, there is a good chance the holes will misalign.
See the how to rivet section below.
Step 4
For the second hole, you can measure and mark the location or you can eyeball it. Just make sure that you are punching through both pieces of metal.
Once punched, rivet the second hole as well.
Step 5
Repeat this process for the other bend on the first side and both bends on the second side.
Riveting
When riveting together surfaces you will need rivets and a rivet gun
Rivets are placed in the material short side down
The longer portion of the rivet will go in the rivet gun
Belowm is an example of a rivet flush with material
Example of how to rivet below!
Using a rivet gun requires two steps:
Once the rivet is fully seated shown above. Press the handles completely closed and then open all the way
Repeat step 1 again
Closed
Opened
Success!
Remove end of rivet from rivet gun to continue
Sanding
If the top of the box is uneven, use the belt sander to even out the surface
Holding the material on the sander for an extended time will cause the material to get hot! š„
Lid
Step 1:
To account for size differences in making the box, measure the sides with a pair of calipers and mark the bends for the lid lips on your lid piece.
Align it so that the box is along one of the longer edges of the top piece. There should be about 0.5" margin on all 3 sides.
Step 2:
Cut at the marked corners using the hand shears.
Step 3:
Bend the front lip using the brake.
Step 4:
Bend one of the side lips by putting the front lip at the edge of the brake so that it is touching the front lip.
Step 5:
Repeat with the other side lip on the other side of the brake.
Step 6:
Align the hinge such that only half of it shows above the top edge of the box to mark the holes.
Punch the holes, ensuring that the second largest size (1/8") is in the punch. The holes should be about 0.3" from the top edge.
Step 7:
Fasten the bottom of the hinge with screws and nuts. Use a hex key and a wrench or nut driver to tighten them.
For this hinge we are using a 3/16" long 4-40 screw and nyloc nut.
Step 8:
Placing the holes on the lid for the hinge is the trickiest part. Tape the top part of the hinge on the lid and test how it closes and opens. Once you get it in a place that seems good, mark the holes by scratching them through the tape and punch those out.
Step 9:
Fasten the last two screws and you will have a finished box!
