How to Build a Case Out of Sheet Metal

Sheet metal cases fit nicely in the back of trucks and other larger metal bins. They work well for organizing heavy tools such as wrenches and other metal equipment. Cases like these are meant to take abuse and to keep equipment separated from other fragile gear. Build a simple case out of sheet metal using only three sheets, a metal bender and a MIG welder. Knowing how to use this equipment properly will ensure the quality of your sheet metal case.

Welding gloves
Welding jacket
Welding hood
Tape measure
Square
Sheet metal bender
Sheet metal, 1/16-by-14-by-48 inches
2 metal sheets, 1/16-by-4-by-20 inches
MIG welder
Band saw
Hinge, 1-by-20 inches

Instructions

- 1
  Bend the 48-inch sheet at a 90-degree angle 4 inches away from the 14-inch edge. Make another 90-degree bend that is 20 inches away from the first so the 48-inch edges make a J-shape. Make one last 90-degree bend so you have a 20-by-4-inch rectangle created by the 48-inch edges. This is the frame to your sheet metal case. Weld the 14-inch edges together on the case frame.
- 2
  Notice the corner edges of the frame. They can vary in roundness depending on your metal bender. Cut the corners of the 20-inch sheets to match the roundness of the frame. Use your band saw. When they are positioned against the open ends of the frame, their edges will be flush with the sides of the case frame.
- 3
  Weld one of the 20-inch sheets to the frame so the corners are flush. Weld half of the 20-inch hinge to the other side of the frame so it can fold over the opening of the frame. Weld the last 20-inch sheet to the other half-hinge so it can open and close. This half-hinge will not be visible when the case is closed. Your case is ready for use.

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