Quick & Easy Sheet Metal Projects - ShopNotes Magazine

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.

2 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 . 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.

3 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. 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.

4 108 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. 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!}

5 /412!/4#/4#/4#/16#/4!/2!/21!/41!!/162223 11!!/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!%/161!!/161!!/16 NOTE: CIRCLED NUMBERSREPRESENT SEQUENCE OF BENDS43213!/4#/4"-DIA.}

6 #/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)!)}

7 /2"-WIDE x !/4"-DEEPRABBET(THREE SIDES)SIDE(9#/4" x 8!/16")NOTE: ALL PARTSMADE FROM !/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!)))}

8 %/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!/8"}