Creating a metal tray using iron sheet, angle rubber, and a mallet involves

metalworking skills, accurate measurement, and a focus on safety. Here's a detailed

guide for this practical project, including key precautions:

Tools and Materials

 Iron Sheet: Choose a thickness that suits your project (e.g., 1–2 mm for lighter
trays, thicker for heavy-duty).
 Angle Rubber: Used to protect corners and edges during shaping.
 Mallet: A non-marring mallet (like a rubber or wooden mallet) for shaping the
metal without damaging it.
 Scribber (Scriber): A marking tool for scoring lines on metal.
 Ruler or Measuring Tape: For precise measurements.
 Metal Cutting Tools: Such as a jigsaw with a metal-cutting blade, an angle
grinder, or metal snips.
 Safety Gear: Safety goggles, work gloves, ear protection.
 Workbench with Vise or Clamps: To hold the metal sheet securely during
cutting and shaping.
 File or Deburring Tool: To smooth sharp edges.

Step-by-Step Guide

1. Design and Measure:

 Determine the dimensions of your tray, including the length, width, and
height of the sides. Sketch the design on paper.
 Measure and mark the iron sheet with a ruler and scriber according to
your design. Include the side flaps for bending.
2. Cut the Iron Sheet:
 Secure the iron sheet to your workbench with clamps or a vise.
 Use a jigsaw, angle grinder, or metal snips to cut along the marked
lines. Wear safety goggles and ear protection during cutting.
 After cutting, use a file or deburring tool to smooth rough edges.
3. Bend the Edges for the Tray Sides:
 Using a ruler, draw bend lines on the sheet to mark where the sides will
be formed.
 For each side, place angle rubber along the bend line to protect the
metal from direct mallet impact.
 Secure the iron sheet in the vise or with clamps, aligning the bend line
with the edge of the workbench.
 Use the mallet to gradually bend the sheet to create the tray sides.
Work evenly along the bend line to avoid distortion.
 Repeat for each side, ensuring consistent angles and dimensions.
 4. Join the Corners:
 Once the sides are bent, the corners will overlap. You can secure them
by riveting, welding, or bending a small tab to hold them together.
 If riveting, use a drill to create holes for rivets, then secure them with a
rivet gun. Wear safety goggles when drilling.
 If welding, ensure you're in a well-ventilated area and use appropriate
safety gear.
5. Final Touches:
 Check the tray for sharp edges and use a file or deburring tool to
smooth them.
 Test the tray for stability and ensure the sides are straight and even.
 If desired, you can add a finish or paint to protect against rust and
corrosion.

Safety Precautions

 Wear Safety Gear: Always wear safety goggles and work gloves during
cutting, shaping, and assembly.
 Avoid Loose Clothing: Wear tight-fitting clothes and remove jewelry to
prevent accidents.
 Secure the Workpiece: Use clamps or a vise to keep the iron sheet stable
during work.
 Cut and Bend Carefully: Avoid excessive force to prevent accidents and
ensure consistent shaping.
 Maintain a Clean Workspace: Keep the area free from debris and tools not in
use.