5. Construction Processes

Base Construction

Mark out and cut a piece of 0.4mm Gal to the correct size (520mm x 430mm).
Using a steel rule, scriber and jenny callipers to mark out all of the necessary fold and cut lines and shown in the diagram (a texta may be used as a contrast).
Centre punch and drill 2.5mm holes at the point of each notch using the hand drill (8 holes in total).
Using tin snips, cut out the notches and corners. Remember: Red Handle = Right Hand, and Green = Left Hand.
Mark out and centre-punch the holes for the pop rivets.
Drill all holes at 3.5mm using the hand drill (14 holes in total).

Triple Fold

Using Magna-bend or Panbrake, fold and flatten the safety edges.
Flip the project over, and fold the second line to 80 degrees (check the angle using the guide on the handle).
Flip the project over again, and fold the third line so that the Safety edge is flat (horizontal).

Tabs

Using either the Magna-bend or the Panbrake, fold tabs up at 90 degrees to the base.
Note: Ensure that the mandrels are placed between the triple folds to prevent them from getting squashed.

Sides

Using the Magna-bend or Pan-Brake, fold the sides up 90 degrees to the base.
Note: Ensure that the mandrels are placed between the tabs to prevent them from getting squashed.

Using the base (YJ = Your Job) to obtain accurate sizes (approximately 220 x 170mm), mark out and cut 2 ends for the toolbox
Note: (Clearly label each end e.g. AA and BB).
Using the Magna-bend fold and flatten the safety edges.
With the safety edge facing up, fold the second line to 90 degrees.
Flip the project over (safety edge facing down). Use the Pan-brake to fold the third line to 90 degrees.
Stay on the same side, fold line four to 45 degrees.
Flip the project over again. Using the Pan-brake, fold line five to 45 degrees.
The end piece may now need same minor adjustments in order for it to fit into the sides of the base (known as teasing).

Carefully line up one side in the correct position (ends should line up just below the triple fold).
Start in one of the top corners, use a power drill and 3.5mm drill bit (to suit the size of the rivets) to drill through the pilot hole and then through the side piece of Galvanised steel (ensure you have the project supported by a block of wood).
Secure the top hole by fixing it in place with the first rivet before drilling the next hole.
Repeat this process with the opposite top corner.
Ensure that the side is in the correct position before finishing the other 5 holes.
Repeat steps 1 to 5 for the opposite side of the box.
An additional rivet may be needed just under the handle to close in any gaps.

Using the base (YJ = Your Job) to obtain accurate sizes, mark out and cut 1 lid for the toolbox YJ + 30mm (approximately 325 x 430mm).
Mark out all of the necessary fold and cut lines shown in the diagram.
Once all marking out has been checked, cut out the notches and corners.
Centre punch and drill 2.5mm holes pilot holes.
Using the Magna-bend fold and flatten the safety edges.
Using the Magna-bend again, fold the tabs up at 90o to the lid.
Fold the first line to 70o.
Pull the lid towards you, move the mandrels back and fold the second line to 30o
Again pull the lid towards you, move the mandrels back again and fold the third line to 30o
Again pull the lid towards you, move the mandrels back again and fold the final line to 70o
The lid will now require teasing in order to have it fit the base.
Once the lid sits easily on the base clearly label each end AA and BB.

Place the lid into the correct position.
Measure the height from the top of each side to the top of the lid then add 10mm (this will be the width of your lid sides).
Now measure the side of your box between the triple folds and add 5mm (this will be the length of your sides).
Cut 2 pieces of Galvanised steel to suit the new measurements (approximately 80 x 215mm)
Check that the rectangle will fit (it should end up a similar size to the base sides).
Using the Manga-bend fold and flatten a safety edge on each piece.
Use the lid to trace the outline of the shape required for each end of the lid (again label each piece AA and BB
Ensure that the safety edges will be on the inside of the lid
Using the guillotine cut carefully along each line. (ensure that each end fits neatly).

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