How to Make Gifts From Sheet Metal

Sheet metal can be both a decorative and a functional material.

Sheet metal is a readily workable material, and though it requires some strength to work with, it can be cut by hand into two-dimensional shapes and bent into three dimensions. This technique can be used to create durable, unique items that are perfect for gifts for friends or family. Items such as candle sticks, lanterns, organizers and mobiles can all be made with a bit of time and a workshop equipped with basic equipment.

Things You'll Need

• Thin stainless steel sheet metal, 3- or 4-gauge
• Pencil
• Tin snips
• Vice
• Clamps
• Wood blocks with curved surfaces
• Hammer
• Metal punch
• Scaffold pole
• Hacksaw
• Metal rod roughly 1/8 inch in diameter
• Brazing torch
• Brazing rod
• Flux
• Safety gloves
• Safety apron
• Safety mask

Instructions

1. 

   Stands can be constructed effectively from bent rod.

   Sketch your gift idea before starting. The best way to work with sheet metal is to mount shapes cut from the sheet onto a stand made from bent metal rod. Imagine the stand of a candlestick or the rings and back of a CD rack. The shapes used in these items can be achieved by simple bending of straight rod. You can purchase straight, thin metal rod from most hardware stores and bend it by hand to the design of your choice. Draw the shapes you will use onto the sheet metal and cut out with tin snips.

2. Bend the sheet metal shapes by pressing them around scaffold poles or locking them in a clamp and pressing them one direction or another. Alternatively, place them over a wood block with a curved surface and hammer against the block. This works especially well for creating bowl shapes.

3. Punch lines of holes in the metal shapes using the hammer and metal punch. Lay the sheet metal on a flat piece of scrap wood. Place the tip of the punch against the point you want to pierce and hold the punch upright. Keep your fingers away from the flat top of the punch and strike the top hard with a hammer. This works particularly well for lanterns or lampshades as patterns of animals, plants or abstract designs can be punched into the sheet metal and then the metal can be placed in front of a light.

4. Print a picture of the desired shape and cut around it to help you with the punching.Tape it to the metal sheet and use a marker pen to mark points around its outline. Punch a hole through each of these points.

5. Bend shapes in metal rods before cutting them to size so that you can use the whole length of the rod for leverage. The metal rods will form the stand or structure of your design and will hold the sheet metal shapes, as per your design. Make sweeping curves and curls such as those seen in an ornate candlestick. Secure scaffolding rods in place with vices and bend the rod around them. Cut the bent sections you require with the hacksaw.

6. Place the pieces you want to join together. Make sure both pieces are really clean. Put on all the welding safety equipment. Cut a length of brazing rod about 10 inches long. Dip the tip of this piece of brazing rod into the flux and scoop out a small amount on the tip of the rod. Flux in a paste form is easiest to work, with but you can do the same with powdered flux. The flux helps the metal form a clean join. Place the tip of the brazing rod with the flux on it over the join you want to make. Heat both the rod and the join with the brazing torch and let the melted rod flow into the join to fix the items together.

Tips & Warnings

• Use 3- or 4-gauge sheet metal as greater thicknesses can be difficult to work by hand. It will also decrease the weight of your item, making it more practical and reducing stress on any braised joins.

• Wear safety glasses when cutting steel and always use heat protective gloves, goggles and a particulate filtering mask when brazing. Braze in a well ventilated area.

References

• Jatayu: Working With Sheet Metal