Use a 20-ton hydraulic press to emboss a design made from 16 gage wire into 22 gage sheet metal. The embossing designs can then be pressed into many different sheet metal projects. This instructable was created by Hyde Middle School students as an instructional aid during their metal shop classes.
Step 1: What you will need
20 ton press
card stock paper
16 gage wire (galvanized steel)
22 gage sheet metal (steel)
Step 2: Make pattern
Cut out a 6 inch x 6 inch card stock that will be used to tape your design onto.
Step 3: Draw a 1" boarder around card stock
Draw a 1inch boarder around the 6 inch x 6 inch card stock material.
Step 4: Draw your design in the middle box.
Try to keep the size of your design limited to the middle box. Keep your design simple. Have your instructor approve your design.
Step 5: Add 16 gage wire
Bend the 16 gage wire to the shape of your design. You may want to use forming pliers or needle nose pliers to help bend the wire. You can bend the wire around just about anything that will help you achieve the shape you want for your design.
Step 6: Tape down wire
Use scotch tape to tape down the wire design.
Step 7: Begin to press
Set finished pattern on the press.
Step 8: Insert 22 gage sheet metal
Set the 22 gage 6 inch x 6 inch piece of sheet metal on top of your pattern.
Step 9: Insert rubber pad
Set the 1inch red rubber pad onto the sheet metal.
Step 10: Pump the lever on the press up and down
Make sure that the pressure valve is turned clockwise until it is closed. Pump until the gauge reads 6,000 lbs. of pressure or until it gets hard to pump.
Step 11: That's it, you're finished!
File all corners with a single cut file until they are rounded. Sand the corners, front and back surface with 220 sand paper. You can put a finish of your choice such as paint, rusting solution, or a clear coat to protect your project. Drill a hole in it the top and you can hang it up to show all of your friends your cool personalized metal emboss.
This Instructable was created by and for Hyde Middle School students for instructional aid during their Metal Shop classes.