If you are not familiar how to make a simple sheet metal box, this article will introduce the simple process of sheet metal box making in detail. It is very easy to make it according to our steps, with only 1/2 elbow. When we entered the process, we first need to define about what material to use to construct the sheet mal box. When I compare the iron box we are working on with the metal box when it is unfolded, we can better understand the structure of the box, but before finishing the iron box, we should think about the correct sequence of operations, and finally make a good sheet metal box, which expands the ability to solve problems.

How to handmake a small sheet metal box

Step 1: Preparation

Tools and Equipment:

A ruler,Iron awl,scissors,Clamp machine,Spot welding machine

Material:

Iron sheet (I have used 22 gauge),sandpaper,Spray paint (optional)

Step 2:Design a Drawing

Before we begin, we need a plan of action. If you can't see the flat (unfolded) pattern of the tin box visually, find an old cardboard box and expand it. The pattern of the carton looks very similar to the pattern of the tin box you need to make.

The size of the iron box we made is 55cm x 20cm x 35cm. This size makes it easier to make and design, so that the design drawings can be folded on paper. If your design plan works on paper, it should work on a tin box.When we design box images and PDF files. Feel free to use it exactly as it is, or just as a template for your own iron box size.

If you have not worked with sheet metal before, there are a few terms you need to know to help you understand these plans.

  • Hem - A piece of metal that has been rolled up onto itself. The hem will be located on the top edge of the box to provide a smooth rounded edge rather than a sharp jagged edge.
  • Bump - Attached metal sheet or strip used to assemble or secure the sheet metal into the desired shape.

Step 3: Build A Paper model of the Metal box

Making models out of cheap (and easy to make) materials is always a good habit when making unfamiliar things. The designed iron box was first constructed from paper before continuing to use iron. The process of constructing the iron box on paper is shown for real comparison with the design, which will make the whole process exactly the same as the real production. When the model is finished, it will be the same size as you planned; Your tin box production should proceed very smoothly. If the simulated sides are not flat, the corners are disconnected, or the angles are too small/large, it might be a good idea to go back to the planning stage and make some modifications to your design.The sequence of this step is as follows:

  • Measure and mark the hem length from the side of the paper.
  • Draw a line parallel to the edge you measured through the marked measurement.
  • Repeat steps 1 and 2 for all edges of the paper
  • Measure and mark the hem and side length from one side of the paper.
  • Draw a line parallel to the edge you measured through the marked measurement.
  • Repeat steps 4 and 5 for all edges of the paper
  • Mark the area of paper that will be used.
  • Measure and mark your tag length, not deviating from your side.
  • Draw a line parallel to the line you measured to create a square for the TAB
  • Repeat steps 8 and 9 for all TAB locations.
  • Tag label
  • Draw lines at approximately 45 degrees to tilt the hem and the AND
  • Cut off any unlabelled parts of the paper.
  • Fold along the row until you have a box.

Step 4: Mark the dimensions

Once the metal material is ready for use, the first step you need to take is to get the metal material to the required size. Measure and mark your overall size measurements on the sheet metal as per your plan. It is important that the lines are well marked and straight. If you do end up marking the lines and angles slightly, it's hard to put the box out as planned.

In this step, we use a foot clipper to cut the metal to size. Foot cutting machine makes this step easy and quick, keeping our metal edges clean and tidy. If you do use a foot clipper, be sure to line up the marked lines in the correct position of the cut before cutting. An accompanying picture shows the position of the marker line just near the edge of the scissors table, which will provide us with the precise measurements we want to make on the scissors. Foot clippers are not required, as you can also use hand clippers to complete this step.The sequence of this step is as follows:

  • Measure and mark desired overall dimensions from metal edges.
  • Use square and scratched awls to mark straight lines on your marks.
  • Cut along the marked lines to bring the metal to the desired size.

Step 5: Layout drawing

Now mark the correct dimensions on the sheet metal and mark the designed layout pattern on the metal. If you have a square, I recommend using it to make sure you mark as straight a line as possible. Overall, if you decide to go through with this step, the process is the same as the simulation. It's just a matter of taking your time and making sure that the lines you're marking are the right ones, and hoping that they're displayed correctly. Below, I list the sequence of operations used.The sequence of this step is as follows:

  • Measure and mark the hem length from the metal side.
  • Draw a line parallel to the edge of your measurement up to the marked measurement.
  • Repeat steps 1 and 2 for all edges of the metal.
  • Measure and mark the hem and side length from the metal side.
  • Draw a line parallel to the edge of your measurement up to the marked measurement.
  • Repeat steps three and four for all edges of the metal.
  • Measure and mark your tag length, not deviating from your side.
  • Draw a line parallel to the line you measured to create a rectangle for the TAB.
  • Repeat steps 7 and 8 for all TAB locations.
  • The marking metal will be used in all areas of the box.
  • Scratch 45 degree lines to tilt all hem and droop.

Step 6: Cutting Forming

With the layout marked, it's time to use scissors to cut your metal into shape. Overall, this step is pretty easy, but using wire cutters on sheet metal can be a real arm strength exercise. Don't go wrong, go slow, take your time, and be sure to cut the area you need to cut.The sequence of this step is as follows:

Use your scissors to cut the metal into shape.

Step 7: Clear the connection area

When you spot weld iron boxes together, you want the connections between the metals to be as clean as possible. This means that before you begin any bending, you will need to clean the part of the metal that will show spot welding. Now, it would be much easier to clean the labels and the sides of the tin case before bending. To do this, you will need to sand the layout treatment solution as well as all the grease on the metal. When we spot weld, this will allow you to have clean metal to metal connections, which will give us the strongest connection.

To do this, just use a piece of emery cloth or some 800 mesh sandpaper to clean the inside and outside surface of the metal, both convex and side.

Step 8: Bottom of the box

As mentioned before, the bottom is only part of the tin box, which has been rolled up. The hem will be located on the top edge of the tin box to provide a smooth rounded edge rather than a sharp jagged edge. To perform this step, a strip clamp is used, but the process can also be performed using metal brakes. The goal of the hem is to make the double metal layer flat without any bubbles or dents. The key to properly adjusting the bottom is to use a knock (not a heavy hammer) and to keep the hammer head flat on the metal. If you push too hard or the hammer tip is slightly tilted, you will eventually leave a dent in the hem. As with all steps, patience is required. Take your time and pay attention.The sequence of this step is as follows:

  • Insert the metal into the strip clamp until you reach the marked bottom line.
  • Pull the handle to fold the metal 180 degrees
  • Remove the metal you are now folding from the strip folder and place it back in the folding table with the folding facing up.
  • Pull the handle to 180 degrees again to better smooth out the double layer of metal.
  • Repeat steps 1-4 for all other hemlines.
  • Place the bottom on an anvil/sturdy surface and flat10 the hem completely with a hammer.
  • Repeat Step 6 with all other hemlines until all hemlines are completely flattened.

Step 9: Bend into an iron box

You're almost done. Once the hem is made, the next step is to bend the metal into an iron box. You will use iron brakes to complete this step. The purpose is to clamp the brake teeth tightly to the production line. If your wire is clamped down at an Angle to the brake teeth, you will bend the metal at an Angle and the iron box will not come out as you wish. In addition, you need to move the gears while resting, or you will not fold the metal correctly. Move the gear at the break until the shorter side can be inserted into the setting below so that the convex part will not be creased during bending.The sequence of this step is as follows:

  • Lift the brake teeth with the clamping lever handle.
  • For this step, the line you should use should be the line that will bend both your side and the convex part. In my example, this will be my "long edge" row. Slide the piece of metal under the tooth and align the marked line with the edge of the tooth.
  • Lower the grip handle to clamp the metal into place.
  • Use the curved leaf handle to slowly fold the sides and convex tongue to 90 degrees.
  • Return the curved blade to a neutral position and lift the tooth to remove the curved metal.
  • Repeat steps 1-5 for the other side of your box.
  • Open the clamp slightly so that your sides and the clamp are not exactly aligned. Use a vice or some pliers for this purpose.
  • Return to the rest and lift the folded leaf, then insert the unfolded edge under the properly placed tooth.
  • Clamp the teeth and thread parallel to each other at the top of the marking thread.
  • Use the handle of the leaf to slowly bend the sides 90 degrees until no further bending can be done without damaging the box.
  • Lift the tooth and remove the folded side.
  • Repeat Steps 8-11 for the other side of your iron box.
  • Bend the tag back slightly to bring it closer to the edge of the side. I use a vise for this purpose, but you can also use a hammer to knock them back into place.

Step 10: Spot welding of iron box

Now the iron box is almost complete! However, without some form of fixation/assembly, the box can easily unfold or deform. To keep it in the desired shape, we need to weld it between the nail and the side of the box. To do this, the tongue will be spot-welded to the side of the box. If you do not have a spot welder, then the mechanical fasteners will also work. If you want to go with nails, I suggest you use something like pull rivets or mechanical screws. You have already prepared the metal for the process in the previous step, so all that remains is the actual spot welding. Always wear all necessary and appropriate PPE (personal protective equipment) when using spot welders. Our spot welder user's manual recommends safety glasses, masks, gloves, open-toed shoes, and long pants.The sequence of this step is as follows:

  • Place the iron box between the electrodes to be welded. This area should be on your label marker.
  • Slowly lower the pedal, pinch the metal, and make sure the electrodes are properly placed.
  • When you are ready, press the pedal down and hold it there until you complete the spot welder cycle. You should hear the electrical loop open and then close. Keep pressing the pedal until you hear the end of the loop.
  • Release the foot pedal and then reposition the box to the next position to be welded.
  • Repeat Steps 1-4 until your boxes are completely held together.

Step 11: The box is finished!

Now the production of the iron box is basically complete! But we still need the lid, as shown in the picture, please repeat the same process, but make the lid of the iron box slightly larger overall, but only design it to be one sixth of the height of the iron box. For painting (decorative colors), use regular spray paint that you can use on a tin box. Be sure to clean the metal by sanding the oil and rust from the tin box before painting. Then make sure to remove any dust or metal shavings left behind.

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Sheet Metal Fabrication-Sheet metal Box