How to make a toolbox out of sheet metal

Written by sarah fardell
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How to make a toolbox out of sheet metal
This project involves welding and metal cutting so wear protective gear. (torch image by Guy Verville from

A sheet metal toolbox can be a very handy item. It's sturdy, lightweight and will not rust. You can use it to store anything from your power tools to the kids' toys. However, sheet metal boxes can be very expensive. If you have some welding tools at home and some time on your hands, you can easily make your own box and save a lot of money.

Skill level:

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Things you need

  • Sheet metal
  • Ruler
  • Permanent marker
  • Two sawhorses
  • Cutting torch
  • Protective goggles
  • Protective gloves
  • Clamps
  • Welder
  • Electric grinder
  • Two large hinges
  • Electric drill
  • Screws
  • One large latch

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  1. 1

    Draw the dimensions of the sheet metal box on your sheet metal using a ruler and permanent marker. The size will vary depending on the intended purpose of the box. Typically you will want six panels in total, with two of them longer, to create a rectangular box.

  2. 2

    Place your steel sheet on top of two sawhorses. Cut along each line with your cutting torch then smooth the edges with an electric grinder. Now you should have six separate pieces.

  3. 3

    Put two pieces together at a time using a square measure to ensure they are perpendicular. Using a clamp to hold them in place, weld them together on both sides of the edge. Repeat for each piece of metal except for the lid. Allow 30 minutes to cool.

  4. 4

    Drill four small holes in one edge of the lid and attach the hinges. Attach the hinges to one side of the box. Drill two more holes in the side of the box and opposite edge of the lid and install a latch.

  5. 5

    Test the strength of your box and reweld any sides that need it. You can use it to store anything you like.

Tips and warnings

  • Use protective gear at all times.

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