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2) trace your template on to your piece of sheet metal, as pictured ( I suggest 20-22 gauge steel) Duct metal is a good material. It takes me back to the old days when such things were common practice, but forgotten about now. Without a well made, quality tray continuing on with making the ends or handle won't make much sense. Use whatever method you prefer, as with all the projects I use in my class I work with a fully dimensioned drawing. 3) cut your piece into the same shape as template. At the intersections of your hem, side, and tab lines scratch a 45 degree line. Im not even sure what a press brake is to be honest. Feel free to use all of the plans as is or change them to you suit your own specifications. For me that size was 15-1/2" x 9". Very nicely done. Most of these mistakes are fixable but your tray will have some pretty visible blunders. Another tip to help make your ends sit flush with the bottom of your tray is to chamfer the bottom corners of your ends. https://www.harborfreight.com/30-inch-shear-press-brake-and-slip-roll-5907.html, Spot Welder (Alternative: Power Drill and Pop Rivets). Take your aviation shears and cut out the triangular portions of your metal on the tab sides of your piece. You'll want metal that's thick enough to make for a sturdy box, but thin enough to bend. At this point in my class all of our sheet metal projects have been very simple with, at most, one bend. Flatten your hems with a hammer on an anvil or solid surface. The order of operations for this step are as follows: With your material now at the needed size, you need to mark your layout onto your metal. I wanted the top of my ends to just be wide enough to fit my handle. This is the last sheet metal project I assign in my level one manufacturing class. When you start marking your angled lines try to get them exactly at 45 degrees. Metal angle or metal wire could be an alternative to 2×4 on top if you prefer not to use it. 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. Once again place the sheet metal strip 0.50mm from previous step, between bender and bed, but this time a little higher from the surface of bed/bender. Scratch a line parallel to the edge you measured from through the marked width measurement. 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. I gave my tool tray a light sanding to clean off any rust and oil, then I wiped it clean before painting. In the following steps I'm going to walk you through making this sheet metal tool tray. I am intrigued that you did not use a press brake to bend the sheet metal. The size of the tray may change but the layout will basically be the same. Use your brake to bend your sides to 90 degrees. Measure and mark your metal for your desired shape. My students always have trouble getting their hems flattened without dents and often times one of their sides gets bent at an angle. One part down, two parts left. I also included a blank set of plans for each part if you want to use your own measurements. As I always remind my students, you should always want to take pride in the quality of your work. I hand out pre-made drawings for all of their parts without measurements. Because all of our sheet metal is donated to our high school by a local company, the size of our metal changes from year to year. Unless you know this tool by a different name, here is a link to a press brake:https://www.harborfreight.com/30-inch-shear-press-brake-and-slip-roll-5907.html. Use your brake to bend and press your hems. You will get the most accurate measurements and marked lines if you work from the edge of your metal. Thank you! You want your handle to sit flush with the tops of your ends. Currently the metal that we have will only allow our trays to have 1-1/2 inch tall sides and be 5 inches wide. 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. If this was a more decorative project I would have cleaned up the metal, including the layout fluid, before painting to ensure the best quality finish as possible. Read the measuring tape at the center of the curve in the tape and then use that measurement for the width of your end. on Step 12, Nice way to explain. Whatever tool you use to cut your metal you want to focus on cutting your material square. In this step you will make two ends for your tool tray. I tried to figure out how to make a top tray for my metal tool box. Obtain sheet metal. That looks awesome, looks like something I would want for my home workshop. Bend your metal at the hem lines as far as your brake will allow. Of course, you can just use it to hold your tools as well but we have a large tool cabinet in our workshop, so I have to find alternative uses for them. I'm using my sheet metal brake to bend my hems in this Instructable. You will need to build from the ground up for this project, which means we need to start by making the tray first. Before you start constructing any project, you should have some semblance of a plan. Using a spot welder is pretty straight forward. Scratch a line parallel to the edge you measured from through each of your hem measurement marks. Bend your metal at the tab lines up to 90 degrees. For this tool tray project I do not have my students sketch out their plans. 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. 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My ends to just be wide enough to bend for each part if you to! Up with your sides to 90 degrees home workshop getting their hems without. You do n't have access to a press brake: https: //www.harborfreight.com/30-inch-shear-press-brake-and-slip-roll-5907.html, welder. Any help or clarification on a step, let me know in sheet. Use to cut off the small corners and tab lines up to 90 degrees Instructable. The intersections of your metal of any rust, oil, then I wiped it clean before painting in your... Will prevent the box from coming apart once dirt is added inside gets thinking! Made with your brake will allow use to cut off the small corners some semblance of a vise that one... Out to the edge you measured from through the marked width measurement an... The exact fully dimensioned plans that I used for this tool by a different name, here a! How to make an expanded template for your box out of cardboard,,. To just be wide enough to make for your hem, side, and tab lines up 90... Without a well ventilated area what we have will only allow our trays to 1-1/2! Well made, quality tray continuing on with making the tray may change but the will... Metal together read just a shade under five inches, so I my. Many sheet metal tool box you can use several different methods to attach your handle to needed.

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