2

FORGE

SOURCING METAL

This kind of box design will work with a variety of
metals. Mild steel is the cheapest but you’ll need
to apply paint to protect it from the elements,
0.5-0.7 mm is a good thickness for hand-folding.
If you have a folding machine, then thicker 1 mm
steel can be used and is slightly easier to source.
Ensure you avoid zinc-coated steel as that is not
appropriate for silver soldering. Stainless steel does
not need paint but you will need to take care when
working it as any scratches will need to be polished
out afterwards. Aim for thinner stainless steel such
as 0.3 mm as it is stiffer and hence harder to fold.
Silver soldering also works well with brass sheet
which can be a good choice for smaller boxes as it
is more expensive than steel.
For small metal orders the delivery charges
can be as much as the cost of the material. Take
advantage of your local Hackspace by clubbing
together on a larger order.

MEASURE TWICE, CUT ONCE
Before starting, check that your sheet is square. If
not, mark off and cut the sheet so you’ve two sides
that are square that you can measure from. One

There are a few specific things to think about when working with

sheet metal.

• Protect your eyes from sparks and metal fragments with^
  some goggles.


• Protect your hands when handling the sharp edges of the sheet metal, leather^
  gloves work well.


• Protect your feet from falling sheet metal and tools with sturdy steel^
  toecap boots.


• Protect yourself and work area from the heat and flame of the gas torch by^
  having a fireproof work area and keeping flammables out of the way.


• Protect your lungs from fumes by working in a well ventilated area.


• Avoid silver soldering zinc plated steel as the zinc will melt and form
  poisonous fumes.

SAFETY

of the best ways to mark out the pattern is a metal

scribe. This has a hardened point so cuts a very

thin line in the metal. It can be hard to see these

lines, so use layout blue or a permanent marker

to provide a background so that the scribed lines

are more visible. You may find it helpful to mark

the folding lines with a dotted line to distinguish

them from the cutting lines. We also like to mark

the pieces to remove with red so that we don’t

accidentally cut off an important tab.

CAN YOU CUT IT?

When cutting sheet metal, it is important to support

the metal close to the cutting line. It is also helpful

to clamp the work to the bench with several

clamps. Make sure you have lots of space to move

around the sheet so you are not restricted when

cutting. For 0.5 mm steel, a hacksaw will quickly cut

Left

Blue helps the scribe

marks show clearly

When cutting sheet

with a hacksaw,

keep the blade at

a shallow angle to

the work

QUICK TIP