How to Make a Metal Box

Follow these step-by-step instructions and see how easy it is to use a hand-held metal brake to bend metal. In this project, a box is made using one sheet of metal.

Highlights:

Step 1: Mark and Cut the Metal
Step 2: Place and Bend the Metal
Step 3: Drill and Rivet

Step 1: Mark and Cut the Metal

Use a marker to draw lines on the square piece of sheet metal where it's to be bent. Use metal snips to cut one line on each corner of the metal to the point that it intersects with another line.

use metal snips to cut lines on metal sheet

Step 2: Place and Bend the Metal

Place the metal on the brake's platform, and align the point to be bent with the seam on the platform. Place the brake bar on top of the sheet metal. Use C-clamps to tighten the brake bar (Image 1). Pull the levers on the metal brake to an upright position to make the bending point (Image 2). Loosen the C-clamps and repeat steps 1 and 2 to make additional bends on the remaining sides of the metal.

- Image 1
- Image 2

Step 3: Drill and Rivet

When folded, the box will have protruding squares of metal. Fold each of these to the outside of the box, against the sides. Drill a hole through each corner of the box as pilot holes for the rivets (Image 1). Use a rivet gun to rivet the corners of the box to secure the sides (Image 2).