How to Make Useful Steel Boxes - Simple Jig with No Folding Equipment Needed
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- čas přidán 4. 06. 2024
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Some of you wanted to see how I made the steel boxes in my last video so here it is. The jig is pretty simple but works fantastic.
As well as making boxes and trays I also plan on making drawers for a few projects using this jig.
As always I'm happy to answer any questions.
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Some of you wanted to see how I made the steel boxes in my last video so here it is. The jig is pretty simple but works fantastic.
As well as making boxes and trays I also plan on making drawers for a few projects using this jig.
No essential craftsman is kind of sad
not sure if it would help, but maybe lever clamps to help hold the larger sheets of metal when cutting, otherwise this jig is pretty awesome. As always well done
The blue one… really sharp looking 👍🏻
Thank you, very much. Looking forward to the drawer video.
I can't find that blue hammered metal paint anywhere. 😭
Handy hint: If you don't own an old caliper to score the sheet with, simply use a new caliper. In only a few passes it will be an old caliper.
Scratch awl is cheaper, yes I know that’s not what it’s for but it works. A drywall screw works even lol
Puede usar un calibre trazador, con punta de carburo. Son baratos, funcionan muy bien y duran mucho tiempo .
😂
Also works with the saw.
Haha 😄 use a Stanley knife, they snap off!
As an old maker, I can say your videos are excellent!
No wasted blabbering, annoying music, or self - aggrandizing comments!
Thank You!
I really like, that you always have an alternative way of doing your projects, if you haven't got the tools. It's super important knowing how to improvise around a problem and using alternative building methods.
Yeah, even if you either have the original tools used, or don't even have the tools for the alternative method, simply seeing the different ways the same task can be accomplished can really help improvisational problem solving skills, at least for me.
Glad you enjoyed it! :)
Agree! It is easy to find very skilled craftspersons (I guess that is the word nowadays...) on CZcams, but here you also get the great teaching skills useful for less experienced/equipped DIYers. All done in a calm and relaxed mature way without "Dude!-shouting" or intrusive music - 🏆
Was working on a project one day with a very wise man.. I said we have a problem here.. he replied.. are you sure it is a problem and not an opportunity? That taught me really how to think outside of the box where most people keep themselves missing out on their true potential.
Your fake childish "name" is apt.
If you're using an angle grinder, harbor freight has an attachment for them called a "Safety Guard for Angle Grinders" , it's a replacement guard for your angle grinder that has an adjustable flat plate so that it can be used like a saw. I used one quite often when I was doing metalwork, it made it real easy to do straight cuts.
Neat project. One of the things that stands out with your projects and videos are the jigs you create. For me, sometimes that is the take away from the video. For someone that doesn't weld, another idea to close the corners would be to only cut one side of the waste square and the fold that over and join with a rivet. Thanks for another video.
It is possible to solder it instead if you don't weld. Just tighten the gaps up with a hammer and then go for it with some flux, torch, and solder
Or use JB Weld epoxy. No heat at all required.
Thanks Mike! Jigs are always fun to make, especially if they make a task easier. The only problem I see with leaving a corner tab to bend and join with a rivet is the bend will be directly where the face you're trying to join to is. You could do it but I don't think it would be very neat. With thinner material and no groove you could bend it a bit further forward. :)
@@PaskMakes Or you will have to keep that in mind and cut the one side on the corner a bit deeper, corresponding the thickness of the material. Your version is cleaner tho, I love the outcome and am gonna try it myself. Thanks for the inspiration!
Oh, just seeing that the grumpy old man sid the exct same thing, nevermind then
You mentioned instead of welding the corners, one might do corner brackets. Another idea would be to not fully remove the corner pieces. Instead, just do one of the cuts and fold over the other. That way you have a bit of overlap at the corner, which yo could very easily drill through and rivet. No extra brackets needed.
A bit of a challenge since the bends wouldn't line up perfectly. You'd have needed to score those slightly offset for that to work.
Soldering the corners could also work
I’m a new welder and just finished making four drawers for my welding cart using angle iron and sheet metal, I really wish I saw this video BEFORE I went through all that! I could have shaved a lot of weight and headache! I’ll definitely use this technique next time!
Mark ur box sides on the flat sheet , then just use angle iron c clamped to ur table with ur flat in between aligned with ur marked out lines on the angle…then hammer away…its really not that complicated . If its thicker metal just put in some relief cuts to bend easier
With lid bent at the same time is easy,
in the 1980s I used to cut 2 blanks like you have done but in 0.7mm Zintec Steel and fold them both sandwiched together at the same time and that would give a tight fitting lid.
Sometimes I did bend them with a sheet of cardboard as a spacer to give clearance while bending for a lose fitting lid.
This was so much easier then working out a bending clearance and marking out ;-)
I am still using my 4" x 6" small tin boxes, they now have a bit of gas welding just on the corners to stop them spreading.
That's a top tip!
Excellent video, I looked up a dewalt cordless metal saw, and added to my wish list for Christmas. I did not know there was such a tool, but now I do, many thanks. As someone suggested, battery trays are a big thing, and I know a few bits of plant equipment that would benefit.
Here is a tip... With metal, strip it and paint it first before you store it. You can see some of the sheet metal is already rusting, removing rust in corners is difficult. If you store any metal IT WILL RUST. Just wipe your metal clean of any oils, and spray it with some spray paint. When you do a project the paint wipes easily off with a bit of acetone, no time wasting removing messy rust.
If the humidity levels are less than 40% then it won't rust, so the trick is to store your metal in the dry desert air.
If you want to spot weld or pop rivet, you could just cut one half of the tab, and fold it in. Beautiful quick project
You'd need to offset the bend by one material thickness though.
Thanks Leif! I already answered this on an earlier comment and 'Grumpy old man' has already answered it here for me, he's right. :)
@@PaskMakes you are welcome.
One could create separate rectangular pieces, scored down the middle bend to 90°, drill holes and used rivets to attach them to support the joints.
Or use a torch and solder (hard/silver) or braze using some flux and copper wire.
Or ....
🙀
Once again you show a deceptively simple design that's really elegant. I can see all kinds of uses for boxes like these. And yes please show the organizer. You are a treasure, Neil. Thanks for sharing this.
Alternatively, you use a tiny diameter in a Dremel with a base. It has the advantage of being able to make stop cuts. The idea of using metal sheets to make drawers is absolutely brilliant! It's definitely faster to make and provides more interior space due to the thinner walls.
Thanks Bob! :)
In aerospace this is known as ‘rout & fold’ method and is generally used on composite sandwich panels.
It was also used on the original composite F1 car monocoque chassis such as what you’d see on early to mid 80’s Lotus’ and McLarens.
In shop class in Jr high and high school this would be the first thing they would show us how to make is a small tool box to make out of metal. To keep are basic tool's in. My brother still has my little metal box I made he keeps his hair clippers in it. It was made with galvanised metal if I remember correctly.
How do you find more names for the various methods in aerospace for metal/composite forms? I want to study various methods but don’t know if there’s a Bible for metal forming in aircraft.
@@princetchalla2441 An FAA Advisory Circular (AC 43.13-1B) has some answers. You will need a fast connection.
Love this video. No wasted time yet, shows everything necessary.
The offset strip that you use to set the position for the scoring lines could be piano hinged right onto the fence. When you want to set the offset, drop it into position, when you are done with it, flip it up out of the way for the saw to pass. You'll never lose it.
Reminds me of the old (and still used) Detroit pizza pans. They used the parts trays from the automotive manufacturing plant to make, in my opinion, the best pizza in the world. I absolutely love the blue hammer finish on that one!
Great idea. Fairly easy to make. And if you have old sheets of metal laying around, i.e. old PC cases your fixing to scrap, and old appliances the larger pieces of sheet metal can be repurposed for more storage. And while plastic has its uses, these trays are more durable.
Perfect timing, Neil. Just got a great deal on a Mig welder and want to do many shop projects, including some steel drawers. With your method, I don't need a metal brake.
16ga is perfect! It’s thicker gauge than most toolboxes, harder to dent or bend under weight and nice and solid. Drop a bunch of sockets or fasteners on it and it doesn’t have a tin can sound
I remember watching the video of you making your welding table a while back, its satisfying to see how useful it is
I had never thought of making these as I don't have a break. This is such a great idea. Thank you for posting this.
Great work Neil! You could recess some neodymium magnets into your play jig to hold the metal down.
Thanks Ben - that would work well, it would attract chips though and there are a lot of them. :)
Not only are you videos very entertaining but the fact that you aim to teach how to do your projects with everyday tools most folks have is really awesome & impressive. You’re one of a kind, Pask!!
Thanks very much Joshua! Glad you enjoy the videos! :)
Good accuate process for this method.
Have used it in the past for trailer fenders and battery trays, free hand with a cut off wheel and a straight board...this is a more refined method.
Did weld a few stiches in my corners because i didn't trust my depth of cut to be consistent.
I turned a wood-cutting blade backwards on my saw years ago to cut a bunch of sheet metal (works really well!) and the sparks melted the housing around the blade. To prevent slipping, cover your jig with the non-slide open-weave matting used for bottoms of drawers in tool-chests. It's used in kitchen cabinets too.
Exactly the video I've been wishing for. Have got a large sheet of thin sheetmetal from a water heater that I've wanted to make a chip tray for my 10 inch south bend lbench lathe. Thanks!
great trick! i've never seen this done before for making boxes or trays. i worry a little about using it to put heavy things in, as the material is only half as thick around the bottom perimeter, but i think that a few stitch welds around the bottom on the inside would make it bulletproof.
I really appreciate that you think about viewers with very limited tool selection! i have tons of tools, but i also appreciate doing projects with just a few hand tools. can't wait to see your next video about organizer drawers.
LOVE the way you explain all the details. Thank you
ok. i'm in *LOVE* with the simplicity of this! Thanks!
Only YOU could make this topic so exciting to watch. Thx Neil!!
You never cease to blow me away with your skills!
I love to see a craftsman at work.....great stuff.
I like the jig. I've made boxes before by slitting the length of the bend and then leaving a couple tabs connected. Then bend by hand and weld. It was a lot more welding than scoring the length of the bend as shown in the video.
Nice video. I also used this technique of grooving the steel sheet before bending. I used it for making feet for a compressor tank. However, I welded up the bends on the inside after bending, with a MIG/MAG-welder, to restore the integrity of the parts. It is a very easy way to bend somewhat thick sheet metal.
Thanks, and q:
Should the groove be at outer or inner side of the angle?
Been doing this for a long time with aluminum. The best part about that is you put a jumky blade in your table saw you can do all of it without the jig. Never really occurred to me to try it with steel though so I dig it.
That would work, not for steel though! Thanks! :)
@@PaskMakes You can cut 16ga steel on a table saw just as easily as you can cut it with a circular saw.
Very timely mate, I need storage bins in my 'workshop' and have a load of sheet steel. Been looking at making a folding jig but this method looks way easier. Thank you very much.
Good luck with that project! Sounds fun, I wish I had a workshop to organise
Glad it was helpful Mark! :)
Can make focaccia pan with this technique 😋👍
This is just what i needed. Basically im fitting 3rd row seat from an e-nv200 combi into a van equivalent. I need a recess in the floor where the fold down leg goes. These boxes will be perfect with a lip welded in to bolt to the van floor.
I'm not a metalworker but you've given me some ideas for small boxes in wood. Thanks!
Fantastic. Love the way your brain works. Woodworking or metal working, your videos are the best.
I do it just by scratching the sheets with a broken saw blade for metal saws, but I use ways thinner sheets, that's a really great way to do it, not just another DIY tutorial to make something worth two bucks but you need a workshop worth 1/4 million bucks, like usually, this method is doable with basic tools, even in a flat if one doesn't have the space for a workshop. Thank you 🖖
Less is more 😊👍
Nice jig. For the strip you use to set the adjustable fence, you could attach it to the main fence with a hinge and then just flip it up out of the way when cutting. This would keep it with the jig and prevent accidentally using it for another project or throwing it away.
I've never seen a metal blade like that here in South Africa. I'd like to get a few 👍
Thanks for sharing your skill 🙏
One of your cleverest projects ever Neil! Thanks so much!
Thanks very much Capt Buscemi - glad you think so! :)
@@PaskMakes you could make it even cleverer by adding triangles to the jig that would allow you to cut a many sided base and create a hexagonal, or a hexacontagon if it pleased you. You could create some nifty little metal boxes with them!
I made custom pizza baking pans from this inspiration thank you. I removed mill scale and washed and seasoned them 8 times and they are perfect! The heavier gauge retains heat.
Reminds me of sheet metal projects I did in Jr. High where we made a simple toolbox with a pull-out tray.
LOL, I watched lots of your videos as a long-time subscriber, but I just now realized you're an Aussie. I'm Swedish but have been to your lovely country a couple of times since my Brother and later Mum'n'Dad moved there decades ago. To me, hearing your voice adds to the greatness of your videos Aussie Aussie Aussie Oi Oi Oi 😁👍
That has to be the best way I have ever seen an advert done on you tube
Great tutorial. I enjoy watching confidence and competence.
I like these simple and practical projects. Thanks Neil.
Glad you enjoyed it! :)
Even though I’m not a metal worker, it’s a 👍 from me.
Forgotten how sharp sheet metal can be, especially in working with a large piece in a cramped garage space.
I have used this technique with an angle grinder with the thin cutting disks designed for stainless steel and the diamond disks as used in the cutting of ceramic tiles.
The blade guard can be adjusted to position it against the cutting guide and the depth of cut can easily be determined by eye.
The first pass is a quick light stroke followed by one or two subsequent passes.
The advantage of this method is the equipment is inexpensive, readily available and the disks are operating at their optimum performance.
Not having to use a metal brake is a real game changer. Great vid and fantastic results
Nice build/discussion/demonstration
Nice job Mate ! Those little boxes will last for years. Better than any plastic bins ! Liked the idea of cutting half way thru for the corners / edges. Worth making the fixture.
Very impressive! You are a great instructor.
A chatted with a contractor who was making a lab, and the upstairs storage was floored with diamond plate. He had an old Blue Ryobi circular saw he was using for cutting the steel. He bought something he wasn't going to mind losing quickly for cutting some plate, figuring to buy something better suited if he got more of those kinds of jobs and after the saw died. Several years later and although being used more than he thought for cutting steel (and occasionally wood as a spare saw) it was surprising him with how long it was lasting.
That's great to know, thanks! :)
Those have a million uses... I love it.
Looks like a an ideal way to make steel cases for tools of custom sizes....
INCREDIBLE Craftsmanship!!!!
That blue paint looks nice. I love hammer tone.
This is a textbook presentation, thank you so much. you have solved a lot of problems And answered all my questions.
legend ❤
Nice job 👍. Thanks for showing the build.
the boxes look perfect for the oil pan used to make Detroit deep pan pizzas. the metal cutting circular saw runs lower on the rpm's
1st drill pilot holes into the corners, this is the first lesson of every metal worker. Bends better and makes alignment easier.
I need to make some metal drawers to fill a couple of empty slots in an old industrial rack I have. I may just try your technique. Thanks for sharing!
Bravo, simple but quite effective process.
very cool Sheet Table build
Good stuff Pask. Wishing you and yours a great 2023. Darlington, South Carolina USA
Looks super useful! And I've been meaning to put a metal cutting blade on one of my old spare circular saws
You will prob find the higher rpm of a wood saw kills the metal cutting blade very quickly. Or I did any way !
Wonderful! I won’t make any because I don’t do any metal work. If I did I could as you are amazing!
Great watch
Bob
England
These would make great drawers too. Well done, sir.
Would be great to see how you would make a press fit lid for a box
Handy trays for pulling things apart for repairing etc. I'm not sure if there's such things as magnetic sheets but if so,
Magnetic trays are really handy to avoid losing bits.
Great video Neil 👍🏼👍🏼
Magnetic sheets definitely exist, or just buy a whole roll of fridge magnet and cutting it to size
Love you Pask, you are the man!
That's really great and gave me an idea for the mailbox I am planning to build.
You always put top stuff out. Love your work
I'm definitely making this jig. Great work!
Love to see that organiser you mention at the end Pask !
Just brilliant. Cheers for sharing.
awesome idea to use the circular saw and a jig 👍 using the angle grinder freehand is always tricky do get the depth consistent, and usually a single cut is a little too narrow...
Great ideas and nice job!
If you plan on making a bunch of boxes, I'd suggest getting some quick workholding clamps and putting holes for bolts in the jig, and bolting a pair of clamps on the side so you don't have to manually hold the sheets.
You can also easily make a jig for holding the box while you drill holes if you're going for the riveting/bolting angles to the corners.
Those quick clamps are great for jigs.
I appreciate you letting us know those were old calipers. :)
You are astoundingly clever, sir. I love your videos.
It turned out great !
I love that jig!
Wow, that jig does seem like a time saver.
I'll be copying this one soon, fantastic work.
Brilliant work, Neil! Really well done! 😃
If you use stainless steel sheets you can use those even for cooking!
Stay safe there with your family! 🖖😊
Thanks very much! :)
Great ideas for me coming out of your shop. That’s for sharing!
Amazing technique! Thanks for sharing.
I've done this with 1/4" plate steel before but welded it afterwards to put the strength back as this weakens the corners considerably, for your purpose it will still be as strong as needed though.
That Jig is genius, thanks!!
I honestly thought you were making baking pans until I watched the video..
Nice work. I'm sure you'll find a million and one uses for metal pans in your shop. Very nice.. 👍
If you use stainless steel, these could easily be made as baking trays I reckon. 😁👍🏻
Good show as usual Neil! Efficient use of time with this jig!
Thanks very much! Glad you like it! :)
Well done and thank you for sharing this gem.
Great idea for making a chassis for valve amplifiers. Thanks.