Quick & Easy Sheet Metal Projects - ShopNotes …

1 ShopNotes No. 108 Page 1 of 7 2009 August Home Publishing. All rights reser & easy Sheet metalProjectsWorking with Sheet Metal isn t difficult if you have the right tools. All it takes to make the items shown here are some basic tools, a pair of tin snips, and the Metal brake featured in ShopNotes No. 108. You ll also need the patterns on the following pages for laying out the cuts and bends. I think you ll discover that after fabricating these few simple proj-ects, you ll be ready to design and build your own. And to me, that s half the fun of being in the shop applying what I ve learned to build something that s practical and Metal .

2 The first thing I want to talk about is Sheet Metal . You ll find it in a variety of thick-nesses, or gauges. The higher the gauge number, the thinner the Sheet Metal . For shop Projects like these, 22-gauge steel is about right. It s easy to cut and bend but still has plenty of strength. Layout. With the patterns on the following pages and your Sheet Metal in hand, it s time to lay out the project . Then all you need to do is cut out the pattern, make the bends, and spray on a coat of paint. The end result is a set of handy Projects for your shop. Simple Shelf. Page 2 Storage Tray. Page 3 Tool Rack. Page 4 Bit Rack. Page 5} Drawer Case & Drawers. Starting on page No. 108 Page 2 of 7 2009 August Home Publishing.

3 All rights reser : CIRCLED NUMBERSREPRESENT SEQUENCE OF BENDS4563271#/4#/4#/4#/16#/81!/21!/25&/8 18101!/84#/8#/44#/4 NOTE: SHELF MADEFROM 22-ga. Sheet Metal { Strong and Sturdy. By following the pattern below, you ll create a strong shelf complete with braces. A few simple bends with a Sheet Metal brake make it VIEW44#/4#/4 ShopNotes No. 108 Page 3 of 7 2009 August Home Publishing. All rights reser TrayPATTERN7!/219!/41233%/83%/8#/8%/8 NOTE:CIRCLED NUMBERSREPRESENT SEQUENCEOF BENDS4561372%/161!/2#/16 NOTE: SHELF MADEFROM 22-ga. Sheet Metal { Storage Tray. After drilling the mounting holes in the Sheet Metal blank, cut out the shape shown in the pattern.}}

4 Then you can make the bends to form the flanges and VIEW%/83!/23wall-mountedShopNotes No. 108 Page 4 of 7 2009 August Home Publishing. All rights reser RackPATTERN8!/412!/4#/4#/4#/16#/4!/2!/21 !/41!!/16222311!!/16!%/16!%/16!/2" : CIRCLED NUMBERSREPRESENT SEQUENCE OF BENDSNOTE: RACK MADEFROM 22-ga. Sheet Metal { Drill & Bend. To create this wall-mounted tool rack, you start by drilling the holes. To complete it, you then make the four bends, as shown in the drawings and pattern VIEW221!/41 ShopNotes No. 108 Page 5 of 7 2009 August Home Publishing. All rights reser accessBit RackPATTERN!/4!/4129!/4 2!/22!/21!/421!}

5 %/161!!/161!!/16 NOTE: CIRCLED NUMBERSREPRESENT SEQUENCE OF BENDS43213!/4#/4"-DIA.#/4(/16#/16"-DIA.# /4#/4!/4" GROMMET(McMaster-Carr #9307K64)!/2" GROMMET(McMaster-Carr #9307K85)NOTE: RACK MADEFROM 22-ga. Sheet Metal { Safe Router Bit Storage. Rubber grommets help protect the delicate cutting edges and shafts of your router bits. The drawings below show you how the rack is VIEW#/4" !/412!/22!/2 GROMMETShopNotes No. 108 Page 6 of 7 2009 August Home Publishing. All rights reser drawerCaseSIDE(9#/4" x 8!/16")BOTTOM(9#/4" x 7!/4")BACK(6#/4" x 8!/16")TOP(9#/4" x 7!/4")!/2"-WIDE x !/4"-DEEPRABBET(THREE SIDES)!/2"-WIDE x !/4"-DEEPRABBET(THREE SIDES)SIDE(9#/4" x 8!/16")NOTE: ALL PARTSMADE FROM !)}

6 /2" PLYWOOD FRONT VIEW1!#/163#/47%/85!!/167!/48(/168!/16#/ 8!/4!/4!/8!/8" { Simple Plywood Case. This easy -to-build case holds the four drawers shown on the next page. Simple saw kerfs serve as the drawer No. 108 Page 7 of 7 2009 August Home Publishing. All rights reser !/21!/21&/86!%/169#/8#/8!/4%/86!/243215 NOTE: CIRCLED NUMBERSREPRESENT SEQUENCE OF BENDS!/8!/4#/8!/41(/16sheet metalDrawerDRAWER BOX(22-ga. Sheet Metal )DRAWER FRONT(%/8" x 1&/8" - 6!%/16")NOTE: FOURDRAWERS REQUIRED{ Fast & easy Storage. With four of these drawers and the case shown on the previous page, you can create handy storage for small items. And it doesn t take up much space on a VIEW91&/8 NOTE:ATTACH DRAWER FRONTUSING FINISH NAILS!))}}

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