Step 3: The Enclosure
I got inspiration for the techniques I used in crafting this enclosure from this instructable by Improbable Construct: http://www.instructables.com/id/Homemade-Mini-Press-Brake/
I started with a very basic form of that press brake, knowing that I would not need very sharp angles. really, I just took 2 equal lengths of 2x4, and put them together with 2 heavy duty hinges that I had lying around. I used a piece of 1x4 cut to the same length as the gap between the hinges to clamp my sheet metal in place.
I used a sheet of plain 22 Gauge steel from home depot. It measured 12"x18",
I measured out and marked both long sides of the steel. I wanted the front to be 2" tall, the back to be 4" tall and the top to be 8" from front to back. I also left 1" to curl under the bottom at the front and 1" at the back. these lips would serve as a place to secure the sides.
Using my makeshift pressbrake, I bent the sheet metal into shape. I had to fold the back a little extra by hand, as I could not achieve a 90+ degree bend with my rig. This was easy enough to do.
Once I had the metal bent, I traced the shape onto some 1x6 maple I had from another project. I cut this out with a jigsaw, made a second copy, and sanded them until they fit just right. I drilled pilot holes through the metal and put drywall screws into the sides to hold them in place.
I started with a very basic form of that press brake, knowing that I would not need very sharp angles. really, I just took 2 equal lengths of 2x4, and put them together with 2 heavy duty hinges that I had lying around. I used a piece of 1x4 cut to the same length as the gap between the hinges to clamp my sheet metal in place.
I used a sheet of plain 22 Gauge steel from home depot. It measured 12"x18",
I measured out and marked both long sides of the steel. I wanted the front to be 2" tall, the back to be 4" tall and the top to be 8" from front to back. I also left 1" to curl under the bottom at the front and 1" at the back. these lips would serve as a place to secure the sides.
Using my makeshift pressbrake, I bent the sheet metal into shape. I had to fold the back a little extra by hand, as I could not achieve a 90+ degree bend with my rig. This was easy enough to do.
Once I had the metal bent, I traced the shape onto some 1x6 maple I had from another project. I cut this out with a jigsaw, made a second copy, and sanded them until they fit just right. I drilled pilot holes through the metal and put drywall screws into the sides to hold them in place.
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