Intro

In my shop classes many of my students come into class with almost no workshop/hands on experience. I don’t mean just no experience working with tools, but many of my high school students don’t even know how to read a ruler/tape measure. This beginner sheet metal project provides a quick, simple project that allows them to gain some experience completing a shop project and to learn and practice their newly rediscovered measurement skills.

If you’re looking for a project to get your students, or yourself, started working with metal this is a great little project you can do with minimal tools and a small amount of material. If you are looking for a more practical application for this project you can use the same process to make name plates for drawers or containers in your shop or classroom.

Tools and Materials

Tools

• Ruler

• Scratch Awl

• Number/Letter Stamp Set

• Hammer

• File

• Center Punch (optional)

• Drill (optional)

• Clamp (optional)

Materials

• Sheet metal (I used 19 gauge)

• Sandpaper (optional)

• Clear Coat Spray Paint (optional)

• Layout Fluid (optional)

• Scrap lumber (optional something to drill into)

I always make my students work from a set of plans when completing a project. In my class this project used to begin with every student drawing out their own set of plans following my example in class, which ended up looking like the image above. I've since transitioned away from having the students make their own plans and have started giving them the plans, this way I can focus on teaching them to read a technical drawing first before teaching them all the proper ways to draw their own.

Below you can find the plans I have my students use to make this project. Feel free to use these as is or just as a reference for your own design. The rest of this project works off the set of plans I use in my classes but the steps would be the same no matter the size you decided to make these dog tags.

Insert plans here

Prep Work - Cut Stock Piece

The dog tag project is usually the first project I have my level one students complete so I cut up a bunch of blanks for them to use. This speeds up the process and allows the students to focus on reading the drawing and measuring correctly instead of worrying about cutting this small piece of metal to the right size.

Following the plans I use I cut a bunch of 1" x 2" dog tag blanks I give to my students when they are approved to start working in the shop on this project.

You can use a simple set of shears to cut the sheet metal to your desired size. Aviation/compound snips (you may refer to these as tin snips) work fine, especially if you're just making a couple dog tags.

I cut up all my blanks in bulk using a foot shear. Any method you use to get them to the size you need should be fine.

Layout

Follow your plans to mark your reference lines. Use a ruler and a scratch awl to complete this process. These lines will be used to help position and center the stamped numbers and letters on the metal.

Because we are going to use a ruler as a straight edge when laying out the lines, be sure create two marks for each measurement. This gives will give you two reference points to utilize to help mark the lines as straight as possible.

Order of operations for the layout are as follows:

1. Measure and mark 1 inch in your width direction.

2. Measure and mark 3/8 inch from the top of your piece.

3. Measure and mark 3/4 inch from the top of your piece

Stamp

Time to stamp the metal with whatever you want the dog tags to read. My class' simple dog tags include just the first initial and last name of the student on the top marked line and the current year stamped on the bottom line.

You can have the dog tags read whatever you want. Email address? Gamer tag? Turn them into labels for shop drawers? Go crazy with it!

The order of operations for stamping are as follows:

1. Gather the letter/number punches you need and put them in the order of what you want your dog tags to read.

2. Place your blank on an anvil and tape down two opposite corners.

3. To make sure your name is centered work from the inside out (This is where your 1inch marked line comes in handy.) As an example I punched "J COOL" into this dog tag. I started by punching the "C" just to the left of the 1 inch line and then an "O" directly to the right of that same line. I continue that process until the full name is punched.

4. Repeat steps 1-3 as necessary until your dog tag has all the information you want punched onto it.

Round the Corners

You now want to soften the sharp corners of the rectangular metal dog tag with a file. You’ll need something to hold your metal while you work as well. A vise works great but a simple clamp can work fine too.

The order of operations for this step are as follows:

1. Secure your dog tag into the vise with the corner you need to file slightly sticking out. (Don't clamp to tight or the jaws of the vise may put marks on your metal.)

2. Run your file across your metal at a slight angle away from you.

3. Continue to run your file across your metal, working the sharp corner into a nice rounded corner.

4. Repeat steps 1-3 until all your corners are rounded.

Drill Hole (Optional)

For this step you will need to use your hammer, center punch, clamp, and drill. (I used a 1/8" drill bit.)

If you don't want a hole in your dog tags, or you are using these steps to make something other than a dog tag just skip to the next step.

The order of operations for this step are as follows:

1. Use your hammer and center punch to create a small dimple in your metal. This will give your drill bit a place to start.

2. Clamp the dog tag down. (Never drill into metal without first securing it in place first.)

3. Place your drill bit into the dimple, make sure you keep the drill bit at a 90 degree angle to your metal and drill your hole. (Don't press too hard, let the drill bit do the work and cut through the metal.)

Clean Up and Finish

You do not need to use layout fluid for this project. You should be able to see your layout lines fine without it. I don't have my students use any and their dog tags always come out looking pretty good. If you do use layout fluid, once you are done with all your fabrication, use some sandpaper to remove the fluid from your metal.

If you are using sheet metal that is going to rust quickly I recommend applying some form of finish to your dog tags. A simple clear coat will keep the metal look of your project intact if that is the look you are going for. Generally, you will need to apply two to four coats of the clear coat to provide the best protection from rust. Feel free to finish them in whatever color you would like or with whatever finish you have on hand that will work on metal.

The order of operations for this step are as follows:

1. Use sandpaper to remove any paint, rust, or oil from your metal. The metal should be nice and shiny on all sides when you are done.

2. Use a dry rag/paper towel to wipe your dog tag clean of dust

3. Apply your finish to your dog tag.

Project Complete!

There you have it! Finished dog tags!

This is a really good, small project to that I used to help my students gain some shop experience and practice essential measurement skills.

If you are looking for another good beginner project try out these Sheet Metal Vise Jaw Covers.

If you have any questions, comments, or advice on sheet metal projects please let me know in the comment section below or message me at shopclassbuilds@gmail.com.

Enjoy creating, teaching, and learning!