Sheet Metal Tool Box

This Toolbox will take your sheet metal skill to the next level. It looks simple enough but has a few tricky folds and marking out the sides it is a bit more challenging than you would expect.

The rail at the top also doubles as storage for sockets, so a handy little box if you repair cars or trucks.

You will need a few hand tools to mark out your box, and a guillotine, folder, and spot welder.

Supplies

• Pair of dividers
• Scriber
• Steel ruler
• Square
• .55 mm galvanized sheet metal.
• Tin snips
• guillotine
• folder or sheet metal brake
• spot welder or pop rivets

Step 1: Learning Intentions and Success Criteria

Learning Intentions

• To work safely in the workshop.
• To bulid a sheet metal toolbox using a design and instructions.
• To use hand tools correctly and safely.
• To use sheet metal tools correctly and safely.
• To be a self-directed learner.

Success Criteria

• I understand the safety rules and I am working safely in the workshop.
• I can follow the instructions independently.
• I can produce a toolbox and follow the instructions.
• I can safely use marking out tools, tin snips, mangabend, spot welder and files correctly.

Step 2: Making the Base

Start with a piece of .55mm galv sheet 440 by 300 mm. It is very important that it is cut square and to the correct size. Best to use the sheet metal guillotine for every cut you can, as it will keep everything straight and the edges will be cut without any sharp pieces.

Click on the photos for directions and the drawing with all the measurements you need.

Step 3: Making the Handle

The handle is similar to the base but has tags on both ends which are a little more difficult to fold. Cut a sheet 460 X 120 make sure it is square.

Click on the photos for directions and the drawing with all the measurements you need.

Step 4: Marking Out the Sides

The sides are the most challenging part to make, you can make a little tool to help which is shown in the photos. It just a strip sheet metal 15mm wide with 45 degrees cut on each end.

Cut a sheet 200 X 110mm to make a start

Click on the photos for directions and the drawing with all the measurements you need.

Step 5: Folding the Sides

The sides a re by far the most difficult part to fold, some of the bends need to be done on the side of the bender to avoid damage to the sheet.

Click on the photos for directions

Step 6: Assembly and Welding

Welding is also a little tricky, make sure that that handle fits before you start.

The handle needs to be fitted after the base is spot welded or you won't be able to get the weld into the bottom.

Click on the photos for directions