quick & easy sheet metal

Projects

Working with sheet metal isnt 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. Youll also need the patterns on the following pages for laying out the cuts and bends. I think youll discover that after fabricating these few simple projects, youll be ready to design and build your own. And to me, thats half the fun of being in the shop applying what Ive learned to build something thats practical and long-lasting.

Sheet Metal. The first thing I want to talk about is sheet metal. Youll 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. Its 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, its 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.

Shelf
{ Strong and Sturdy. By following the pattern below, youll
create a strong shelf complete with braces. A few simple bends with a sheet metal brake make it easy.
4 #/4

simple

END VIEW
NOTE: SHELF MADE

FROM 22-ga. SHEET METAL

#/4

18 1!/2 #/8 #/4 1!/2 4

3
#/4 #/16

5&/8

#/4

6 5

PATTERN

7 4

#/4

2
#/4 #/8 10

1!/8

NOTE: CIRCLED NUMBERS

REPRESENT SEQUENCE OF BENDS

ShopNotes No. 108

Page 2 of 7

2009 August Home Publishing.

All rights reserved.

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.

enclosed

END VIEW

3!/2

NOTE: SHELF MADE

FROM 22-ga. SHEET METAL

%/8

19!/4 %/16 1!/2

4
#/16

%/8

7!/2

CIRCLED NUMBERS REPRESENT SEQUENCE OF BENDS

NOTE:

PATTERN
5

1
%/8 3 12 3 %/8

#/8

ShopNotes No. 108

Page 3 of 7

2009 August Home Publishing.

All rights reserved.

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.
2

wall-mounted

END VIEW

1!/4

NOTE: RACK MADE FROM 22-ga. SHEET METAL

12 !/4 #/4 !/2 #/4

#/16

PATTERN
3
!/2" DIA.

2 3 !%/16 1!!/16 2

8!/4

4
1!/4

2
2 1!!/16 #/4 !/2

!%/16 1

NOTE: CIRCLED NUMBERS

REPRESENT SEQUENCE OF BENDS

ShopNotes No. 108

Page 4 of 7

2009 August Home Publishing.

All rights reserved.

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) 2

easy access

END VIEW
2!/2

GROMMET

#/4" DIA.

1!/4

NOTE: RACK MADE

FROM 22-ga. SHEET METAL !/2"-I.D. GROMMET (McMaster-Carr #9307K85)

2!/2

12 (/16 #/4 #/16"-DIA.

PATTERN
3

2!/2

1!/4 9!/4 #/4"-DIA. 2!/2 !%/16 1!!/16 1!!/16

1
3!/4 #/4 #/4 2

NOTE: CIRCLED NUMBERS

REPRESENT SEQUENCE OF BENDS

!/4 !/4

ShopNotes No. 108

Page 5 of 7

2009 August Home Publishing.

All rights reserved.

sstacked drawer

Case
7!/4 #/8 !/4 !/8

FRONT VIEW
{ Simple Plywood Case. This easy-to-build case holds the
four drawers shown on the next page. Simple saw kerfs serve as the drawer slides.

!/4

8(/16 8!/16 5!!/16 3#/4 1!#/16 !/2"-WIDE x !/4"-DEEP RABBET (THREE SIDES) !/8"-RAD. ROUNDOVER 7%/8

(9#/4" x 7!/4")

TOP

(9#/4" x 8!/16")

SIDE

(6#/4" x 8!/16")

BACK

NOTE: ALL PARTS

MADE FROM !/2" PLYWOOD (9#/4" x 8!/16")

SIDE

(9#/4" x 7!/4")

BOTTOM

!/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
DRAWER BOX

{ Fast & Easy Storage. With four of these drawers and the case
NOTE: FOUR
DRAWERS REQUIRED

shown on the previous page, you can create handy storage for small items. And it doesnt take up much space on a shelf.

(22-ga. SHEET METAL)

SIDE VIEW
NOTE:
ATTACH DRAWER FRONT USING FINISH NAILS BLIND RIVETS

1&/8

DRAWER FRONT
(%/8" x 1&/8" - 6!%/16")

!/8"-RAD. ROUNDOVER 9 !/4 #/8

1!/2

#/8 1!/2

!/4

!/2

1(/16 !/8

!/4 #/8

6!%/16

PATTERN

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.