How To Weld A Sheet Metal Box

Hi guys say i want to make a simple sheet metal box preferably with the top edges.

How to weld a sheet metal box.

Tig welding sheet metal forget the larger 1 8 inch tungsten electrode and use a smaller one. Take the sander and carefully polish the weld. Then finsih the joint from the inside so your gtaw tip can cross from one side to the other. Step 2 use the cutting torch to cut out each panel and then grind the edges smooth with the hand held grinder.

The patterns for a cardboard box will look very similar to what you need to plan out for the sheet metal box. Best deal on goodyear air hose check this out https amzn to 3b5cjvy. The box i have my students create in class ends up being 5 5 x 2 x 3 5. Making a patch panel take some time to make your patch a perfect fit.

Butt welded panels withstand stress better than any other type of weld joint. To weld sheet metal with solid wires use electrode positive ep or reverse polarity. The best way to weld sheet metal panels together is by butt welding which is joining them side by side see picture below. 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. Lay out the panels for your box on the sheet metal using the measuring tape and the permanent marker. Lay the bottom on the ground and weld the two ends on first. Clean the box with a paper towel and some acetone.

You ll have better access from the outside but a much more difficiult weld. 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.