Woodworking Plans

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Woodworking Plans Design and Construction of Composting Facility. 3. Box type composting. 3. Plan and decide on the composting plant layout. 4. Plan the required key features. 7.

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By robertbaruch in WorkshopMetalworking

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Woodworking Planshow to Woodworking Plans for the 1 last update 2020/05/30

Introduction: A Riveted Metal Box With Lid

Woodworking Planshow to Woodworking Plans for This is a practice box, so it''re not going to touch upon bend radii or bend allowances, but these are important subjects if you want to get into anything more precise.

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Step 1: Tools and Materials

We will make the box out of 0.032"") aluminum sheet metal. You''m using 6061-T6 aluminum. Feel free to experiment with different alloys.

You will also need:

* Left and right sheet metal shears
* A spring-loaded punch
* Cleco pliers and at least 18 cleco fasteners, 3/32"" diameter, 0.225"" and a hole size of 0.097"")
* An air-powered or manual pop riveter
* A thin permanent marker
* A small file
* A square with ruler
* A metal shear
* A box brake

Not shown:

* Two long-nose locking pliers
* At least a 2 3/4"" wide aluminum hinge, without holes
* A drill
* A 3/32"" drill bit
* A #40 drill bit
* A drill bit somewhat larger than 1/8"" would work.
* Preferably, calipers
* A vertical bandsaw or a hacksaw


Step 2: Making the Sides (part 1)

We start the box by making its sides. The sides will be 3"", but we add 1/2"" x 3 1/2"" x 12"" x 12"" pieces from that strip.

With the marker, mark off a line 1/2"" away from one long edge. These are your bend lines.

Where the lines intersect, use the spring-loaded metal punch to put dimples in the metal. This is where you will drill, and the dimple helps to prevent the bit from wandering around.

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Now we need to figure out the measurement of the body that fits around the sides. To do this, we need to take into account bend allowance. The diagram shows what happens when you bend a piece of sheet metal. The bend allowance is the size of that messy bit in the middle which you need to know.

The next diagram shows how a side would unfold, including its bend allowance. So what we need is a piece of metal that is 2 x H, plus W, plus 2 x bend allowance, whatever that is. There are calculators on the web, but just use 1/32"" length, and mark it as shown in the diagram. From one edge, mark off a line at H plus 1/32"" from that, and another line H plus 1/32"" away from the edge.

Make a paper template with three lines, each 1"" bit.

Cut off the corners as before, and file the edges smooth.

Now use the box brake to bend at the lines into a U-shape.

The result should fit together as shown. If not, you may have to adjust the bend allowance if the sides aren''t fit.

Step 6: Match-drill the Holes

Next, we''t take much.

Now put it back together with the clecos.

Step 7: Rivet the Box

Woodworking Planshow to Woodworking Plans for Now it''ll have to redo the measurements for the lid.

As with the procedure before, draw a line 1/4"" bit, attach the lid to the hinge with locking pliers, match drill with the #40 bit, cleco, take apart, deburr, cleco together again, and rivet.

In the image, I''ve made!

Look at the box and think about how you would make the lid fit better. Maybe attach a handle to the lid. Spray paint it.

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    2 Discussions

    0
    stechi

    6 years ago on Step 11

    Nice job, and well explained!     Most people don''t have a home-made alternative to clecos. (anyone help here?)

    0
    robertbaruch

    Reply 6 years ago on Introduction Reply 6 years ago on Introduction

    Nice! I've seen people use screws with wingnuts in place of clecos. It takes a lot more time and effort, though. Clecos are comparatively more expensive: anywhere from $0.75 to $1.00 each.