quick & easy sheet metal Projects Working 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 projects, 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 long-lasting. Sheet Metal. The first thing I want to talk about is sheet metal. You’ll find it in a variety of thicknesses, 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 } Drawer Case & Drawers. Starting on page 6. Tool Rack. Page 4 Bit Rack. Page 5 ShopNotes No. 108 Page 1 of 7 ©2009 August Home Publishing. All rights reserved. simple Shelf { 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 easy. 4 #/4 4 END VIEW NOTE: SHELF MADE FROM 22-ga. SHEET METAL #/4 18 1!/2 4 1!/2 #/8 #/4 3 #/16 #/4 5&/8 #/4 6 PATTERN 7 4 4 5 #/4 2 #/4 1 #/8 1!/8 10 NOTE: CIRCLED NUMBERS REPRESENT SEQUENCE OF BENDS ShopNotes No. 108 Page 2 of 7 ©2009 August Home Publishing. All rights reserved. enclosed Storage Tray { 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 sides. END VIEW 3!/2 NOTE: SHELF MADE FROM 22-ga. SHEET METAL %/8 3 19!/4 %/16 7!/2 #/16 PATTERN NOTE: CIRCLED NUMBERS REPRESENT SEQUENCE OF BENDS 2 %/8 4 1!/2 3 5 6 3 7 1 %/8 3 ShopNotes No. 108 12 Page 3 of 7 ©2009 August Home Publishing. #/8 3 %/8 All rights reserved. wall-mounted Tool Rack { 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 below. END VIEW 2 2 1!/4 1 NOTE: RACK MADE FROM 22-ga. SHEET METAL 12 !/4 #/4 #/16 PATTERN !/2 #/4 2 3 !%/16 3 !/2" DIA. 1!!/16 2 8!/4 4 1!/4 2 2 1!!/16 1 #/4 2 !%/16 1 !/2 NOTE: CIRCLED NUMBERS REPRESENT SEQUENCE OF BENDS ShopNotes No. 108 Page 4 of 7 ©2009 August Home Publishing. All rights reserved. easy access Bit Rack { 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 made. !/4"-I.D. GROMMET (McMaster-Carr #9307K64) END VIEW 2 2!/2 #/4" DIA. GROMMET NOTE: RACK MADE FROM 22-ga. SHEET METAL 2!/2 1 !/2"-I.D. GROMMET (McMaster-Carr #9307K85) 12 (/16 #/16"-DIA. #/4 1 4 PATTERN 2!/2 3 1!/4 9!/4 2 #/4"-DIA. 2!/2 1!!/16 !%/16 1!!/16 1 3!/4 2 #/4 NOTE: CIRCLED NUMBERS REPRESENT SEQUENCE OF BENDS #/4 ShopNotes No. 108 Page 5 of 7 ©2009 August Home Publishing. !/4 !/4 All rights reserved. 1!/4 sstacked drawer Case FRONT VIEW 7!/4 #/8 { Simple Plywood Case. This easy-to-build case holds the !/4 four drawers shown on the next page. Simple saw kerfs serve as the drawer slides. !/4 !/8 8(/16 7%/8 8!/16 5!!/16 TOP 3#/4 (9#/4" x 7!/4") 1!#/16 !/2"-WIDE x !/4"-DEEP RABBET (THREE SIDES) !/8"-RAD. ROUNDOVER SIDE BACK (9#/4" x 8!/16") (6#/4" x 8!/16") NOTE: ALL PARTS MADE FROM !/2" PLYWOOD SIDE (9#/4" x 8!/16") BOTTOM (9#/4" x 7!/4") !/2"-WIDE x !/4"-DEEP RABBET (THREE SIDES) ShopNotes No. 108 Page 6 of 7 ©2009 August Home Publishing. All rights reserved. sheet metal Drawer { 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 shelf. NOTE: FOUR DRAWERS REQUIRED DRAWER BOX SIDE VIEW (22-ga. SHEET METAL) NOTE: ATTACH DRAWER FRONT USING FINISH NAILS BLIND RIVETS 1&/8 9 !/8"-RAD. ROUNDOVER DRAWER FRONT (%/8" x 1&/8" - 6!%/16") 9 1!/2 #/8 3 !/4 #/8 1!/2 !/2 !/4 4 1(/16 !/8 !/4 #/8 6!%/16 PATTERN 5 6 2 %/8 1&/8 1 NOTE: CIRCLED NUMBERS REPRESENT SEQUENCE OF BENDS ShopNotes No. 108 Page 7 of 7 ©2009 August Home Publishing. All rights reserved.