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Directions: Develop a basic knowledge of metals machines and materials by creating a sheet metal box in an industrial lab.


  1. Complete safety tests for the metal hand tools, spot welder, and sheet metal tools.

  2. Obtain a piece of sheet metal from the instructor.

  3. Using the squaring sheers cut the piece of sheet metal to the following size, 5" X 8".

  4. Laying the sheet metal flat on the table, begin the measuring procedures. Measure in a 1" line, all the way around. Connect the measurement lines with a dotted line representing the folding line.

  5. At each end, looking at the diagram, measure a 1/4" line out from the 1" fold line. These lines will become your fold flaps for connecting the corners of the box.

  6. Check with the instructor for the further cutting of the flaps and folding procedures. The instructor will also give you feedback on further improvements.

  7. It is not time to fold the box. Begin by going to the Pan and Brake machine. By placing the end of the sheet metal at the 1" fold line, which includes the fold flaps, fold the ends up to a 90 degree angle, do the same at the other end. You now should have the 2 ends folded at a 90 degree angle, including the flaps.

  8. At this moment, remove some of the Pans from the machine. The pans that remain should fit into the area of the pan that needs to be folded. Place the unfolded area between the remaining pans.(Before folding, a word to the wise, bend the large or middle part are of the folded area out, so that the flaps will go inside the folded area). Now fold the side area up, the flaps should be in the inside of the box. Repeat the procedure on the other side.

  9. At this time, the box should be folded in the upward positions. Now take a small ball-peen hammer and move to a vise-pound on the corners so that they fir together tight.

  10. Now, go to the spot welder for the welding of the corners. Spot weld each corner 2 times. The weld should not break. If help is required, see instructor.

  11. The box should now be able to hold water and not leak. See instructor for further improvements.


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