SHEET METAL FABRICATION
SHEET METAL PROJCET
SHEET METAL TOOL TRAY
Introduction: Sheet Metal Tool Tray
Download the project HERE
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| Sheet metal Project |
These tool trays are great to have around the
house or workshop. They also work great to hold small bolts and parts in the
shop. step further after you make a tool tray, try designing a full tool box
for this
Step 1: Tools, Materials, and Parts List
Tool/Equipment List
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Ruler
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Try Square
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Scratch Awl
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Aviation Shears
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Foot Shear (optional)
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Sheet Metal Brake
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Hammer
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Anvil/Solid Surface
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Spot Welder (Alternative: Power Drill and Pop Rivets)
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Tape Measure
Material List
·
Sheet Metal ( I used 22 Gauge)
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Layout Fluid (optional)
·
Emery Cloth/Sand Paper
·
Spray Paint
Parts to Make
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1 - Tray
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2 - Ends
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1 - Handle
Step 2: Planning
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Before you start constructing any project, you
should have some semblance of a plan.
A quick sketch on the back of a napkin, or a full-fledged
neatly dimensioned drawing. Use whatever method you prefer. Use the drawing provided and go through and
add in the dimensions we will need to know to make each part.
For this project, the tool
trays dimensions are as follows: Length-> about 14 inches long,
Width->7 inches
wide, Height:-> 2 inch tall sides.
GI sheet gauge 28
The size of the tray may change but the layout
will basically be the same.
Use all the plan and the dimensions to
fabricate the tool tray. Use the links below to download the detailed drawing.
Drawings
Step 3: Cut Tray Metal to Size3 More Images
You will need to build from the ground up for
this project, which means we need to start by making the tray first. The first
step will be to cut your metal to the overall size needed to construct your
tray. That is, 15-1/2" x 9".
You may use a foot shear for this step, its
quicker and will leave metal with a clean smooth edge, but you could do the
same thing with a pair of aviation shears.
Whatever tool you use to cut your metal you
want to focus on cutting your material square.
If your rectangular piece comes out more
rhomboid or trapezoid in shape, you're not going to have a fun time marking
straight lines and crafting a quality tray.
The order of operations for this step are as
follows:
1. Measure and mark your
overall length measurement from one edge of your metal.
2. Scratch a line
parallel to the edge you measured from through the marked length measurement
3. Measure and mark your
overall width measurement from an edge adjacent to the edge you just measured
from.
4. Scratch a line
parallel to the edge you measured from through the marked width measurement
5. Cut along both lines
Step 4: Layout Tray
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With your material now at the needed size, you
need to mark your layout onto your metal.
Use a scratch scriber and try square to
measure and mark the lines for your tray.
You will get the most accurate measurements
and marked lines if you work from the edge of your metal.
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.
The order of operations for this step are as
follows:
1. Measure and mark your
measurements for your hem from each long edge.
2. Scratch a line
parallel to the edge you measured from through each of your hem measurement
marks.
3. Measure and mark your
measurements for your side from each long edge.
4. Scratch a line
parallel to the edge you measured from through each of your side measurement
marks.
5. Measure and mark your
measurements for your tabs from each short edge.
6. Scratch a line
parallel to the edge you measured from through each of your tab measurement
marks.
7. At the intersections
of your hem, side, and tab lines scratch a 45-degree line.
Step 5: Cut Tray to Shape
This portion of the project is quick and
simple. Take your aviation shears and cut out the triangular portions of your
metal on the tab sides of your piece. Be sure to cut right on your line to get
those 90 degree angles that you want. Try to not cut in past your tab line.
Step 6: Bend Into a Tray24 More Images
Take your time with this step. Without a well
made, quality tray continuing on with making the ends or handle won't make much
sense. Make straight bends and work through all the operations in this step in
the correct order. If you perform bending/ folding operation in hurry and fold
the side line before folding the tabs or they fold the sides before folding and
flattening the hems, the final product will not be good.. Most of these
mistakes are fixable but your tray will have some pretty visible blunders.
Sheet metal brake may be used to bend hems.
After bending your hems, take your time
flattening them out.
As you use your hammer to flatten your hems
your metal will most likely begin to curl up.
Straightening out the curl in your metal again
is easy and will have no effect on the rest of the construction of your tray.
But, if you are not paying attention as you hammer your hems flat the curling
up of your metal will cause you to put dents across your hem.
Overall the dents won't affect your tray's
usefulness as a container but it will not look as good as it could.
Always to take pride in the quality of your
work.
The order of operations for this step are as
follows:
1. Bend your metal at the
hem lines as far as your brake will allow.
2. Place your bent hems
back under the teeth of your brake to press them down even further.
3. Flatten your hems with
a hammer on an anvil or solid surface.
4. Bend your metal at the
tab lines up to 90 degrees.
5. Bend your metal at the
side lines up to 90 degrees.
Step 7: Make the Ends
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One part down, two parts left.
In this step you will make two ends for your
tool tray.
There is no bending in this step you just need
to follow your plan and cut your ends to the size and shape that you want. I
chose to use just a simple angular shape.
To cut your metal to the correct size for your
ends, use a measuring instruments to measure the inside of your fully formed
tray.
Another tip to help make your ends sit flush
with the bottom of your tray is to chamfer the bottom corners of your ends.
Always make sure that the top ends are as wide
as possible.
The order of operations for this step are as
follows:
1. Measure the inside
width of your tray
2. Measure and mark your
metal to your needed width and height.
3. Cut your metal to
size.
4. Measure and mark your
metal for your desired shape.
5. Cut your metal to
shape.
Step 8: Attach Ends to Tray3 More Images
You can use several different methods to
attach your ends to your tray.
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Spot welding is one of the method.
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If you don't have access to a spot welder, you can use rivets or
some other mechanical fastener of your choice.
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Soldering if the material is light.
To spot weld you will want to clean your metal
of any rust, oil, or layout fluid first. If your metal is not cleaned you may
not get as strong as weld as you would like. Also, if the metal isn't clean
enough you may not have a good enough connection for the spot welder to work.
Be sure your ends are positioned the way you
want before you place your first spot weld, as once that first spot is welded
you won't be able to move it again. If your end is positioned at an angle when
that first weld is placed, your end will be positioned at that angle from that
point forward.
Using a spot welder is pretty straight
forward. Position your electrodes over the area you want to weld.
Step 9: Make Handle
The handle is the last part of you need to
make for your tool tray and the most difficult piece to bend.
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.
Your hems are rather small so folding them
with your brake will require a little more force than your other bends up to
this point.
Once the hems are bent and pressed down, don't
forget to flatten them out to the best of your ability. All of your bends will
be made with your brake besides when you bend your tabs. Your tabs will be
easier to fold with the use of a vise.
The order of operations for this step are as
follows:
1. Measure and mark your
metal to your needed length and height.
2. Cut your metal to
size.
3. Measure and mark your
hem lines from the long edge of your metal.
4. Measure and mark your
side lines from the long edge of your metal.
5. Measure and mark your
tab lines from the short edge of your metal.
6. Cut your metal to
shape.
7. Use your brake to bend
and press your hems.
8. Flatten your hems.
9. Use your brake to bend
your sides to 90 degrees.
10. Use your vise to fold
your tabs down to 90 degrees.
Step 10: Fasten Handle to Ends
This is the fastening. Again, use whatever
method to attach your handle to your ends that you would like.
You want your handle to sit flush with the
tops of your ends.
This will be the same process as attaching
your ends to your tray, so just like before, be sure to have your handle
properly positioned before spot welding, riveting or soldering
Step 11: Finishing and inspecting the product
To keep your tool tray in fighting shape for some
time, you should finish it in some way.
Painting or oiling is one of the method to
keep off any rust. wipe it clean before painting or oiling. 2 More Images
DONE! After your paint is dry your tool tray
is finished and you can use it for whatever purpose you can come up with.
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