Sheet metal is metal that has been made into a thin sheet. It can be made of a variety of metals, including aluminium, steel and stainless steel. Aluminium is soft and easy to work with, though it is not as strong as other varieties of sheet metal. Sheet metal is also available in different thicknesses. The thinner the metal, the easier it will be to work with.
Making a metal tray is simple project that uses sheet metal and that can accommodate multiple skill levels. Trays can be made in any design that you like: standalone trays with each side bent upwards for carrying objects or wall-mounted trays that act as shelves. (See shopnotes.com.) If you make a wall-mounted tray, you can create a tray that is flat with one side bent down at a right angle for mounting or you can create a tray that is bent on three sides to make a secure box when mounted to the wall.
Wall-Mounted Tool Rack
A tool rack requires only a single piece of sheet metal, which can be bent to create a space for tools. (See shopnotes.com.) Holes are drilled for tools to fit into and the rack is mounted on the wall with screws. This is a convenient way to store small tools, such as screwdrivers. To store larger tools, such as hammers, you can drill larger holes. To make this simple project distinctive, use a coloured variety of sheet metal.
A toolbox is an easy way to store and transport your tools. A more complicated project than a shelf, a toolbox is still a relatively simple sheet metal project. The toolbox is made of two pieces of sheet metal that are bent into a box and a top. You will need to buy a handle, lock and hinges from a hardware store to complete the project. (See metalprojects.no-IP.com.)
Sheet Metal Mural
This project works well for a school or club activity. If you are working with children, have them draw designs or characters that they would like to see on the mural. Then cut these out of sheet metal yourself. If you are working with teenagers, you can have them draw the designs and teach them to cut the sheet metal. Secure each metal design or character to the mural space. This can be the side of a building or an indoor or outdoor wall. (See riesniemi.com.)