Diy Play Workbench

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By TeacherMike in WorkshopMetalworking

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Introduction: Sheet Metal Tool Tray

This is the last sheet metal project I assign in my level one manufacturing class. This is the first multiple part project my students work with in class that they will have to assemble for 1 last update 2020/07/10 together. I like this project because it makes the students read multiple sets of plans, use all their knowledge and skills from previous projects. I only give the students just enough metal to make all the parts of the tool tray, which forces them to plan out their entire process before starting. My students enjoy making this tool tray and it is one of the projects that former students always come back and say they still have theirs from when they were in high school.This is the last sheet metal project I assign in my level one manufacturing class. This is the first multiple part project my students work with in class that they will have to assemble together. I like this project because it makes the students read multiple sets of plans, use all their knowledge and skills from previous projects. I only give the students just enough metal to make all the parts of the tool tray, which forces them to plan out their entire process before starting. My students enjoy making this tool tray and it is one of the projects that former students always come back and say they still have theirs from when they were in high school.

If you are new to simple sheet metal work and are looking for some more beginner projects to start with, check out my other sheet metal Instructables where I detail how to make DOG TAGS, VISE JAW COVERS, AND A SIMPLE BOX.

These tool trays are great to have around the house or workshop. I have several of them around my classrooms to hold pencils, rulers, scissors, or calculators. They also work great to hold small bolts and parts when I have to fix one of our machines in the shop. Of course, you can just use it to hold your tools as well but we have a large tool cabinet in our workshop, so I have to find alternative uses for them. If you are really enjoying sheet metal work and want to go a step further after you make a tool tray, try designing a full tool box for this tray to sit in!

In the following steps I''re not going to have a fun time marking straight lines and crafting a quality tray.

The order of operations for this step are as follows:

  1. Measure and mark your overall length measurement from one edge of your metal.
  2. Scratch a line parallel to the edge you measured from through the marked length measurement
  3. Measure and mark your overall width measurement from an edge adjacent to the edge you just measured from.
  4. Scratch a line parallel to the edge you measured from through the marked width measurement
  5. Cut along both lines

Step 4: Layout Tray

With your material now at the needed size, you need to mark your layout onto your metal. Use a scratch awl and try square to measure and mark the lines for your tray. You will get the most accurate measurements and marked lines if you work from the edge of your metal. When you start marking your angled lines try to get them exactly at 45 degrees. If those angled lines are not at 45 degrees when you bend, your tray your will either have unwanted overlap of metal or big gaps.

The order of operations for this step are as follows:

  1. Measure and mark your measurements for your hem from each long edge.
  2. Scratch a line parallel to the edge you measured from through each of your hem measurement marks.
  3. Measure and mark your measurements for your side from each long edge.
  4. Scratch a line parallel to the edge you measured from through each of your side measurement marks.
  5. Measure and mark your measurements for your tabs from each short edge.
  6. Scratch a line parallel to the edge you measured from through each of your tab measurement marks.
  7. At the intersections of your hem, side, and tab lines scratch a 45 degree line.

Step 5: Cut Tray to Shape

This portion of the project is quick and simple. Take your aviation shears and cut out the triangular portions of your metal on the tab sides of your piece. Be sure to cut right on your line to get those 90 degree angles that you want. Try to not cut in past your tab line.

Step 6: Bend Into a Tray

Diy Play Workbenchhow to Diy Play Workbench for Take your time with this step. Without a well made, quality tray continuing on with making the ends or handle won''m using my sheet metal brake to bend my hems in this Instructable. After bending your hems on the brake take your time flattening them out. As you use your hammer to flatten your hems your metal will most likely begin to curl up. Straightening out the curl in your metal again is easy and will have no effect on the rest of the construction of your tray. But, if you are not paying attention as you hammer your hems flat the curling up of your metal will cause you to put dents across your hem. Overall the dents won''s usefulness as a container but it will not look as good as it could. As I always remind my students, you should always want to take pride in the quality of your work.

The order of operations for this the 1 last update 2020/07/10 step are as follows:The order of operations for this step are as follows:

  1. Bend your metal at the hem lines as far as your brake will allow.
  2. Place your bent hems back under the teeth of your brake to press them down even further.
  3. Flatten your hems with a hammer on an anvil or solid surface.
  4. Bend your metal at the tab lines up to 90 degrees.
  5. Bend your metal at the side lines up to 90 degrees.

Step 7: Make the Ends

One part down, two parts left. In this step you will make two ends for your tool tray. There is no bending in this step you just need to follow your plan and cut your ends to the size and shape that you want. I chose to use just a simple angular shape.

To cut your metal to the correct size for your ends, use a measuring tape to measure the inside of your fully formed tray. Read the measuring tape at the center of the curve in the tape and then use that measurement for the width of your end. When I completed that process the tape measure read just a shade under five inches, so I cut my metal to 4-15/16 inches. Another tip to help make your ends sit flush with the bottom of your tray is to chamfer the bottom corners of your ends.

To get the right height for the start of my angle cut on each side of my hem I put my metal into my tray and just marked my ends at the top of the sides of the tray. I wanted the top of my ends to just be wide enough to fit my handle. 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