Toolbox

The details in Fig. 18.6 show parts of a toolbox which can be made as a sheet-metal-work exercise.

A development is given of the end plates (two required) and these should be drilled at the corners before bending, to avoid possible cracking taking place. Note, from the photograph, that the ends have been pressed with grooves to provide additional stiffening and this can be done if facilities are available.

The bottom and sides are fabricated in one piece and drillings are shown for pop rivets. Drill the end plates using the sides as templates to take account of deformation which may occur while bending the metal plate.

Details are shown of the hinges and some clearance must be provided for their satisfactory operation. Before

Part 1 End plates 2 req'd 1 mm MS

Part 1 End plates 2 req'd 1 mm MS

Development of end plate

Development of end plate

Drill 0 2 holes at each corner before bending

Bend line

10 Holes 0 3

10 Holes 0 3

Part 3 Box lid 2 req'd 1mm MS

After drilling, fold along bend line to this position

33 42 42

Bend line

All holes 0 3

Part 2 Bottom and side panels 1 req'd 1mm MS

Note: All corners may be cut back 10mm to fit flush with endplates

20

196 Inside

68

60

" *

i

0 3 Holes fixings to endplates

All holes 0 3

Part 2 Bottom and side panels 1 req'd 1mm MS

Pictorial view (scale 1 : 4) showing folded sides to internal radius of 2mm also bottom holes for riveting to endplates

0 3 Holes fixings to endplates

Pictorial view (scale 1 : 4) showing folded sides to internal radius of 2mm also bottom holes for riveting to endplates

- Drill 2-0 3 holes Each end on assembly

Part 4 Top support 1 req'd 1 mm MS Assemble under end plates by pop riveting 92

3 holes 0 3

25 25 25

Blank for hinge 8 req'd

Part 5 Assembled hinge 4 req'd 1mm MS

55 ^

or

3

CD CM

—1

t

/

29

20

Part 6 Hasp 1 req'd 1mm MS

.£2 L______________________T.

174

Roll hinge blank to suit MS rod 0 4 x 102 long

Peen over pin at each end

2 holes 0 3

Peen over pin at each end

Roll hinge blank to suit MS pin 0 4 x 26 long

0 10

Part 7 Catch 2mm MS 1 req'd

Part 8 Handle 2 req'd

2 Holes 0 3

Part 9 Handle clips 4 req'd 1mm MS

325

j\

0 4

/|

1/

0 3

N

20

Part 10

Tool tray 1 req'd 1mm MS

Tool tray 1 req'd 1mm MS

Bend lines

Tool tray development

Fold up four sides. Weld or braze corners

Bend Lines Engineering Drawing

Development

Part 11 Tray support bracket 2 req'd 1mm MS

drilling the sides and lids for the hinges using the dimensions given, use the hinges as manufactured to check the hole centres for the rivets. One lid must overlap the other to close the box, so some adjustment here may be required. On the toolbox illustrated, pop rivets were used on the sides and roundhead rivets on the lid. Roundhead rivets were also used to assemble the handle clips. Check also the drill sizes for the rivets used as alternatives are available.

The top support member was pop riveted to the end plates after the catch had been welded on the underside. The slot in each lid slips over this catch to allow a padlock to secure the toolbox.

A tooltray may also be made if required and details are provided. The tray supports also offer added stability and were pop riveted on assembly.

Remove all sharp corners and edges before assembly of each part. The completed toolbox can be stove enamelled, painted or sprayed according to personal choice.

As an additional exercise, copy the given details and produce an assembly drawing complete with parts list. Also, produce patterns to cut the components from sheet metal economically. This example provides useful practice in reading and applying engineering drawings.

Solution shown in Fig. 18.12 (and see Fig. 18.13).

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