Sheet metal bending and drilling jigs
I’m working on a project that needs some sheet metal forming around a box lid to extend the size.
The approach is to fold some sheet steel and then rivet it on to the case using pop rivets. The plan is to use lots so it is more decorative.
The metal was cut to size by the supplier so I just need to form it and drill the holes.
Bending
I did visit my local MakerSpace to see if they had any suitable bending equipment but it was unfortunately it was buried behind a large laser printer so perhaps another time when I’ve something thicker to bend. They also have a large milling machine so perhaps that could also come in handy. Having these as an option definitely opens up scope for different techniques and projects but I still want to get my own workshop up and running.
Whilst at the MakerSpace, I was discussing the Stainless Steel Unicorn and it got me thinking that perhaps I had dismissed a simple approach to forming the metal. A former and a hammer.
I marked up the location to bend using some permanent marker and a scribe. Then clamped the sheet between a thick metal bar and a piece of angle. And finally I tapped it over using a hammer and lots of small hits. Trying to keep the face of the hammer flat against the metal to avoid adding any dints. I’m pleased with the results and have got a good fit on the box, although it did take me a couple of attempts to get it right.
Drilling Jigs
So I can get a good pattern of holes, I’ve designed a couple of drilling jigs in FreeCAD that I can clamp to the metal. I used a sketch and some “equal” constraints to get the spacing then lined up my drilling jig to those points.
The end jig lines up with the end and sides of the metal, and then the side jig can line up with holes already drilled.
I’ve some DIY jobs to do around the house so the drilling will have to wait for another occasion.
Posted in: Rugged Case
Materials: Mild Steel
Tags: Bending
Metal sculpture in brass, mounted on an 1800s French Coin
