How To Weld A Sheet Metal Box

Lay out the panels for your box on the sheet metal using the measuring tape and the permanent marker.

How to weld a sheet metal box.

Clamp the folded corner into a jog or fixture tightly to hold the corner square and pretty then try to tack first weld from the inside at at least two locations. Making a patch panel take some time to make your patch a perfect fit. Step 2 use the cutting torch to cut out each panel and then grind the edges smooth with the hand held grinder. Tig welding sheet metal forget the larger 1 8 inch tungsten electrode and use a smaller one.

The best way to weld sheet metal panels together is by butt welding which is joining them side by side see picture below. To weld sheet metal with solid wires use electrode positive ep or reverse polarity. Clean the box with a paper towel and some acetone. Butt welded panels withstand stress better than any other type of weld joint.

Best deal on goodyear air hose check this out https amzn to 3b5cjvy. Don t attempt to weld thin materials like sheet metal with flux cored wires which put more heat into the base metal. Then finsih the joint from the inside so your gtaw tip can cross from one side to the other. First i create a gap and groove weld to close things up and then a fillet weld to reflect what i really want it to look like.

Hi guys say i want to make a simple sheet metal box preferably with the top edges. You ll have better access from the outside but a much more difficiult weld. Take the sander and carefully polish the weld. Place the sander orthogonal to each surface do not polish directly onto the corner because it will weaken the weld.

I applied a thin layer of lacquer to finish the box but this is optional. The box i have my students create in class ends up being 5 5 x 2 x 3 5.