stompbox: folding metal sheets

[Steben]

Hi there

Someone here with experiences?
I'm wondering whether folding your own alu or steel plates to boxes can be useful

[Nasse]

Yes it can be done. I have seen marvellous pics on this site, some have made artful masterpieces from pieces of junk metal. Not me.

For me the most difficult thing has been cutting the sheet accurately enough.

[Gringo]

Check this thread:

http://www.diystompboxes.com/sboxforum/viewtopic.php?t=17725&highlight=

Have fun!

Edit:

And this:
http://www.diystompboxes.com/sboxforum/viewtopic.php?t=18237&highlight=

[petemoore]

I use shears to cut the sheet.
 I use a large sharp cold chisel, and hammer to score the lines in a quick, evenly done method, it leaves evenly spaced triangular dents along the line cause I tilt the chisel so one corner at a time takes a turn denting, then 'roll it over' so it is leaning the other way and hit it again, the re-index the chisel to make the next two evenly spaced 'dent scores', then the bending goes easy and straight, the top of the bends come out evenly and artfully 'mottled',.
 The other way would be with bender pliers. or
 Three boards, 2 clamps, a heavy bench, and a hammer. Sandwich the workpiece between two boards, with the bend line right where the 'meat' piece protrudes from the two 'bun' boards...clamp that to a heavy bench, use the third board to push the bend near the bend line so as not to end up with a 'curve' but a 'corner', and smash it into submission with a large hammer.
 This stuff is easy, thicker stuff you really need a decent score line for the bend to 'take' nicely, or try the three board method without the scores...I put the score lines in very firmly and repeatedly with a sharp chisel, 'carving a V shape into the metal at the score lines.
 Alot of work, watch the fingers...plan your moves...do a before and after count :roll:  :oops:

[The Tone God]

It can be helpful if you need odd shape or size boxes. What you can do will depend on what equipment you have. For long cuts you can use a shear or a bandsaw, with the correct metal blade, or for odder shapes use a plasma cutter. Then use a sheet metal bender to attain the final shape. If the box is not inheriently attached and secure by its shape fasten the box with screws or weld it with a MIG, TIG, or heliarch.

If you don't have the tools or skills but need something made find a local metal shop, bring a set of drawings, and ask them to build it for you. Generally its not that expensive.

Andrew

[Chico]

I make all of my own boxes.

I purchased a 4 foot by 8 foot sheet of 16 ga. al. from a local metal shop.  I paid just over 50 buck for it, but I figure my cost per box is around 2 bucks or less, depending upon size.  A bb style box uses about 1.50 worth of product.

I use a drywall T square to align straight cuts and cut the sheet metal with a circular saw.  I use a 104 tooth blade and cut REAL slowly.  Then file smooth.

The cuts come out nice and clean.  You have to wear safety glasses and gloves as the saw blade spits out tiny metal dustings.

To bend, I bought an 18" sheet metal brake from Harbor Freight.  I think I paid 18 bucks for the brake on sale, and 4 dollars for the saw blade.

The Great thing about this approach, esp. if you use the dark t-shirt method, is that you can iron on the Tshirt paper to a flat piece of metal.

That means that you can cover both the top and sides at the same time.  Also, you can incorporate all of your drill template markings into the tshirt transfer.  That means that your holes perfectly register with your graphics.  After drilling, bend into box form and you are done.

I use the generic T shirt paper from Staples, and it takes bending and drilling very gracefully.  I have not had a single label rip or tear due to handling (as he knocks on wood).

Here is my big trick.  Not rocket science, but it make my home spun boxes much easier to put together.  I use aluminum screw posts (the kind used to hold sheets of paper together, to screw the bottom onto the remainder of the box.  I drill through flanges on the bottom of the box, insert the threaded screw post, secure with 5 minute epoxy, then use the provided screw to attach the bottom piece.  It looks great and is strong.

Best of luck

Tom