Where to get sheet metal?

[Trimoor]

Where would I get some large panels of sheet metal about 4'x8'x1/16"?
As you probably guessed, I want to build a cabinet made of metal.

Any idea what this would cost?

[photorock]

            The first place that comes to mind is a large Sign Shop. You could try one of them. They would carry what your looking for. They can also cut and shape it for you. If they won't (highly unlikely though) sell it to you they would know where to get it cheap.

[Pieman2004]

You should first try to look for steel suppliers to see if they have any sheets. If not then I would try to call a sheetmetal company, they could sell you some, they might mark it up a bit though it just depends on the people. Sheets are 48" * 120" or 4' * 10'. So that will work for what you want with a little extra. It comes in different gauges as well the higher the gauge the thinner the metal. If you already know all this I am sorry for wasting time.

If you don't mind me asking questions
How do you plan on cutting the sheets?
Are you going to weld it together?

I had thought about making one out of metal in the future, but thought I might not like the sound of a metal cab if I were to bang up against it. Never tried though so I don't know.

Oh yeah a 4' * 10' piece of 22 gauge galvanized might run $20-30
not exactly sure though. aluminum and stainless will be much higher.

[Trimoor]

I can borrow a gas welder/cutter, or use a sabre saw to cut the metal.
I'm actually planning on bending the metal, hopefully arc welding it as it bends.

$20-30 is pretty steep for me, I might build a metal cocktail instead.
Would ungalvanized be much cheaper, or is it better to get galvanized anyway?

I guess its to the yellow pages for me...

[Apollo]

A metal cab is a HUGE job dude, you may want to reconsider. You are going to need to use at least 3mm mild steel and doing this will make your cab weigh at least 400 pounds. Add that to the problem of having zero flexibility in the cab joints as opposed to wood and screws, zero margin for error in the constuction and a huge metal object with it's own magnetic field surrounding your monitor and you've got a major project on your hands. Aluminium may be one way to go but good luck cutting and welding it ( it's highly flammable at high temperatures ).
Love to see how this turns out though.

[Mameotron]

Ungalvanized (you only get galvanized if you ask for it that way) will be cheaper, but be warned: when they manufacture steel thay coat it with an oil to keep the rust down.  That crap gets everywhere.  And you will be amazed at how fast it rusts after you wipe off the oil, especially your welds.

You will have to prime & paint this, which is not easy.  You should spray it, and you really shouldn't use spray cans.  It's like painting a car, you really have to know what you are doing for it to come out nice.

I think 1/16" is too thin, I would go with 1/8" (20 gauge).  I don't think it would make it any more heavier than a cabinet built froom wood.  Since I haven't seen your plans I can't estimate what it would weigh.

Ask around, I can readily buy sheet steel in 4x8 sheets (just like plywood)!!  Steel supppliers are the best.  There is a steel mill about 40 miles from where I live, but they only sell by the truckload.

If you are going to flame cut, be prepared to spend LOTS of time with your grinder.  You just won't get a nice edge that way.  A plasma cutter would work much better, but those are really expensive.

Zero margin for errors?  What do you mean by that?  Anyone with welding experience can see that there is plenty of room for error with pieces that are not cut exactly right.  Cut a little more off, or fill the gap with weld.  It is just like woodworking.
The whole point of the joints is that they are NOT flexible.  This is what gives your structure the strength it needs.  The more jounts you can eliminate by using bent sheet steel, the better.  A welded joint is stronger than the steel it connects.

Having said all this, I don't even want to think about all the problems you will have with connecting your controls, computer, etc. so they don't ground out on your cabinet.  I doubt that there will be any effect on your monitor being in a metal cabinet.  Anyway, I would love to see you do this, I think it could be a really awesome project.  You've got your work cut out for you here.

[bwest]

Assuming you are in the states, call your local Roofing distributor, (Bradco Supply, Gulfside Supply, ABC Supply, Allied Supply, etc.)  Most all of them sell 4x10 sheet in 26ga through 16ga. and most common sizes in stainless and aluminum sheet.  

If you go with steel, you will have to whipe down the entire surface with muratic acid to etch the surface in order to get paint to adhere.  Some of the distributors listed above may sell a product called "Paintgrip" which is simply galvanized sheet pretreated for paint.

A sheet of 26ga 4x10 is about $20 retail, heavier gauges go up in price quickly, expecially with the steel shortage right now.

Working with steel can really challenge your tools and patience.  If you do not work with very sharp tools, you will "work harden" the surface and have a heck of a time drilling or cutting.  However, the idea is very interesting.  I hope you proceed and share your story.  Good luck.

[GameDork]

I have been a machinist for years and have MANY tools to my disposal, and wold NOT even think about dong an ALL metal cabinent!! The 2 main reasons are:

1: Expense, you have to take into account that you WILL screw something up beyond repair. i.e. drill a hole in wrong place or sideways , bend this the wrong way etc...

2: Headache, man that would be a job, MANY hours. You would be suprised at how long it takes to make something simple out of steel. I made a simple 6" brake this week, to bend some brackets for someone here, and it took around 8 hours!! And I had to throw a couple pieces away due to a small screwup.


Mameotron, actually 1/8" is .125" and 20gauge steel is .036" thick

BTW, Didn't SirPoonga make a steel COVERED cabinent?

[Trimoor]

Looking back, I can see I wasn't clear when I mentioned bending the metal.
What I meant was to shape it into a gradual curve, probably not even enough to break the memory of the metal.

My total welding experience is about 40 minutes, but I have soldered for years.
I just don't see how it would be that difficult to do.

I cut the individual pieces out, then weld the edges from the inside,
Grind the external corners, wipe with hydrochloric acid, (that stuff is fun ) prime and paint.  (I have an air compressor painter)

As for electronics, the metal is a blessing.
No RF worries, so you can mount the motherboard to the wall.
Obviously, you would have to use spacers, but this is how motherboards are mounted anyway.

[Tilzs]

I think you should use dimond plate

[Pieman2004]

I honestly don't think that making it out of metal would take any longer than making it out of wood. I mean you'll have to design it, which might take a little time, but the actual construction time would be similar(IF you have tools to work with the metal). I don't know about the expense though. I haven't bought enough of either material. But I'm sure a sheet of metal isn't much more than a sheet of mdf or plywood, not a noticeable amount of difference anyways.

This completely changes if you do not have tools to work with metal. Then the process would definitely become tedious.

[Trimoor]

I've got some carbide whatever tipped metal drill bits, metal sabre saw blades, grinders, and access to welders.

Anything else I would need?

[Pieman2004]

It's really hard to say what all you are going to need. It hard to think of, until it comes to the point that you need something. But you might also need some vise grips to hold pieces of metal together while welding.

With a saw, the cuts might not be as clean as you want, but if you are welding those areas it won't matter.

I personally would get angle iron for the frame, but I've never built such a thing so wouldn't know from experience. If you were to build a frame of angle iron, you could then get thin metal to skin it with.

Just ideas I thought I'd throw out there. As I thought about how I'd build such a thing. I was thinking I would weld up an angle iron frame. Then I would attach the metal "skin" with pop rivets(I thought the look might be neat). I haven't thought very far ahead though as this would mean I would have sharp edges on my cab.(with a 1-year old that wouldn't work out).

Thats another thing to watch for: Sharp Edges
Sheet metal can cut you pretty bad, pretty easily.

But I am rambling.
I hope there was something useful in this post

[daywane]

electric sheers!
 I use them often, and a file to smooth the edge.
Thats what I used at Toyota Tshoue. motor plant.
I was lucky enough to take a bunch of there scrap home (long before I even heard of mame)
I make my CP's out of metal.

as far as being heavy?
you would cut the weight down a LOT going with steel sheets. A 4 x 8 sheet of ply wood is heavy. A steel lap at 3 ft x 10 ft (folded the 10 ft to 5 ft ) I picked up with one hand.

as far as welder I would use a mig.
Open torch can warp the lap quick.

I suck with a stick weld unless I am welding very thick metal

I am also self taught. but I was able to put bread and butter on the table , welding for 2 years.

[spidermonkey]

Trimoor, soldering and welding are two *entirely* different processes. You need to decide what type and what thickness metal you're going to use and that will dictate what type of welder you'll need. Also you have to decide wether you're going to make a frame out of angle or channel iron first and then use peices of sheet metal to create a skin or actually make the cabinet panels out of heavier mild plate steel and weld them together to create the structure. If you plan on working with sheet metal then you'll need either a "MIG" or "TIG" welder. If you go with heavier plate steel then you can use a regular stick welder. You have to know what type of welding rods or wire to use. You have to know how much amperage to use for different thicknesses of metal. You may even have to do some bodywork to the cabinet after all the welding and grinding is done because heat causes metal to distort/warp. I took two years of welding school and have been welding on the weekends for seventeen years and I wouldn't even consider doing this. The cab would weigh a ton even before you add all the componants inside. The idea sounds cool and different but from a realistic or practical standpoint its just absolute overkill. Aluminum would be lighter but its *very* expensive and also *very* difficult and tricky to weld. Aluminum has no iron in it so it doesn't turn orange when it gets hot. It just gets a little bit of a wet look and all the sudden if you're not an experianced tig welder you will blow right through it and the two edges you're trying to weld just melt and dissappear. I don't mean to discourage you but unless you are an experianced welder/fabricator and have all the needed equipment you may be biting off more then you can chew. However, if you decide to take it on and have questions about welding please post them and I'm sure all of us will try to help.

[Mameotron]

lol, GameDork, you are right, of course.  I guessed at what gauge the 1/8 sheet would be...  I shoulda looked it up first.

Seriously, why is everyone so down on building a metal cab?  The only thing holding anyone back from building ANY cab is your skill level.  If Trimoor has welding skills, or knows people that do and are willing to help, this could be MUCH easier for him than trying to learn new woodworking skills.  (Just using it as an example, you may have wonderful woodworking skills)

I have been a Journyman Ironworker for the past 7 years, and this looks like a pretty simple project for me.  But that's just because of my experiences.