Fabrication of toolbox
ARCAYERA, MARK SEBASTIENE
DAIZ, KYLE ANREI
HIRANG, JHON MARK
SERRANO, JHANNA ROSE
To design a toolbox that easily to bring anywhere.
To fabricate the new concept of toolbox.
To familiarize oneself with the difference between using a rubber mallet and a regular
To raise awareness of using and performing safety procedures properly when it comes to
Materials (Galvanized Iron Sheet or GI sheet as main material)
Galvanized iron (GI) sheets are basically steel sheets which have been coated with zinc.
These sheets include a range of hot dip galvanized and electro-galvanized steel sheet. The zinc
coating provides a continuous barrier which does not allow moisture and oxygen to reach the steel.
It reacts with the atmosphere to provide the base steel a protection.
By galvanizing, the protection of the steel sheets against corrosion resistance is improved
by several degrees of magnitude. The corrosion protection achieved by zinc-based coatings is as a
result of the galvanic effect, since zinc is anodic to iron which makes it act a sacrificial metal in
an aqueous or humid environment. However, resistance to surface degeneration can be further
enhanced by the incorporation of top coat on the galvanized surface. Galvanized steel sheets are
also known for excellent shiny surface and formability attributes besides satisfactory peel-off
resistance and fusing of the coating completely to the steel surface.
Gloves protect and comfort hands
against cold or heat, damage by
friction, abrasion or chemicals, and
disease; or in turn to provide a guard
for what a bare hand should not touch.
A file is a tool used to remove fine
amounts of material from a
workpiece. It is common in
woodworking, metalworking, and
other similar trade and hobby tasks.
Bent-handled shears are used for
cutting out and sewing scissors for
trimming seams and facings. Pinking
shears are used to form fray resistant
edges and embroidery scissors are
designed for needlework. Leather
shears cut leather and suede and
rotary cutters produce precise straight
Box and pan break
A brake is a metalworking machine
that allows the bending of sheet
metal. A cornice brake only allows
for simple bends and creases, while a
box-and-pan brake also allows one to
form box and pan shapes. It is also
known as a bending machine or
bending brake or in Britain as a sheet
metal folder or just a folder.
drill, tool used to originate or enlarge
circular holes in solid material.
Usually, drills are rotated by a drilling
machine and fed into stationary work,
but on other types of machines a
stationary drill may be fed into
rotating work or drill and work may
rotate in opposite directions.
Rivets are ideal for supporting shear
and tensile loads, as well as watertight
applications. Just what is a rivet? A
rivet is a mechanical fastener
consisting of a smooth, cylindrical
shaft with a head. Upon installation,
the end of the shaft expands, creating
a “shop head” and fastening objects in
They are used to make high strength
joints in a range of materials,
including metals, plastics, wood and
leather. Typically, the processes is
used for joining plastic or sheet metal.
To enable pop rivets to meet the
requirements of a wide variety of
applications, they are available in
many materials, including: Steel.
The purpose of the marking tool is to
transfer all the little notations that
appear on your pattern, the ones that
tell you where to cut, fold, sew, or
place adjoining pieces. The pattern
instructions work together with these
notations to tell you exactly how to
manipulate each pattern piece.
A ruler can be defined as a tool or
device used to measure length and
draw straight lines. A ruler or
measuring tape can be used to
measure lengths in both metric and
A rubber mallet is a lightweight
hammer-like tool with a head made of
molded rubber or hard plastic and a
wooden or fiberglass handle. Rubber
mallets, sometimes called soft
mallets, are used when you need a
softer blow than even a wooden
mallet might make.
Documentation of Output
RIGHT SIDE VIEW
LEFT SIDE VIEW
Step 1: Cut a piece of aluminum measuring 20 by 24 inches. For a straight cut, use a circular saw
with a metal cutting blade.
Step 2: Bend the metal to make the bottom and sides of the toolbox. Measure 6 inches from each
end and bend the metal 90 degrees using a sheet metal brake. This will create two 6-inch sides
and an 8-inch metal bottom.
Step 3: Cut two pieces of 1-by-8-inch oak to roughly 12 inches in length. These boards will form
the ends of the toolbox.
Step 4: Round the top of the wood boards. Use a compass to mark the rounded top, and use a
jigsaw to cut.
Step 5: Bore a hole for the toolbox handle. Using a power drill equipped with a ¾-inch spade bit,
drill a hole in the center of the boards, 1 inch from the top.
Step 6: Apply a thin bead of silicone adhesive along the bottom inside edges of the metal. Insert
the wood ends, gluing them to the metal to make the box.
Step 7: To reinforce the toolbox, screw the metal to the wood using wood screws. Use two
screws for each side and two screw of the bottom on both ends of the toolbox.
Step 8: Use a hacksaw to cut the metal pipe to 24 inches. Insert the pipe through the two holes
drilled in the wooden ends. This will form the handle.
Step 9: Sand the wood using 120-grit sandpaper and file the edges of the metal with a mill file.
Step 10: Stain or paint the wood ends to finish the toolbox. Let it dry overnight before using.
Why is it necessary to use appropriate tools in fabricating the tool box like using rubber mallet in
straightening the GI sheet instead of using a regular hammer?
When constructing the tool box, it is vital to use proper instruments, such as a rubber mallet
to straighten the GI sheet rather than a conventional hammer, because a mallet may hit a
work surface without leaving any markings, which is its main advantage over a hammer.
Mallets are blunt implements with the purpose of striking something. They’re made to alter
the shape or look of a piece of work. They are often composed of rubber, allowing them to
be used directly on a surface without leaving markings. There are also some wood variants,
though they are less frequent. The purpose of a mallet is to make a softer impact on the
object, preventing scratching and scarring. Although hammers and mallets have a similar
appearance, they serve completely different roles. A mallet is ideal for hitting something
softly, like as smoothing the GI sheet. A mallet is the perfect tool for chisels and similar
What safety procedures are observed during the fabrication?
Proper Training Sessions Training sessions should be given to every member of staff before
they start work, whilst intermittent training should also be given during employment as a
refresher. Proper training should include information regarding the correct use of
machinery and equipment, awareness of occupational hazards, the appropriate working
conditions and the best practice policies. This will prevent any accidents or risks in the
Essential Safety Gear Protective clothing and equipment should always be provided
when handling any machinery or materials, such as: hard hats, goggles, gloves, ear-plugs,
and safety shoes. No jewelry or loose clothing should ever be worn due to the high risk of
getting caught in the machinery. This safety gear will ensure that your employees are
always working in a safe working environment and avoid any workplace hazards.
Tool Inspection and Usage Before starting any metal fabrication processes, tools
should be assessed to make sure that they are in the best working condition. Both manual
and power tools should be inspected for any malfunctions and tested before they are used
in case they need to be replaced. Also, when using tools and machinery, make sure that
your employees are aware of the safety features that have been fitted by the manufacturer
and that they are utilized correctly.
Material Handling Concentration is key when it comes to sheet metal fabrication,
especially when it comes to handling the materials. The sheet metal reaches high
temperatures during fabrication and, if being cut, the edges can become very sharp, so
workers need to stay aware of these hazards. As well as this, employees should always
ensure that their neck and back are supported during the working and handling of materials,
as injuries can be long-lasting and painful.
Regular Maintenance Routine It is an important safety precaution to undertake
regular maintenance procedures and inspections to ensure that all machinery is working
efficiently, repairing or replacing where necessary. Faulty machinery can put your workers
at risk of injury, so it is vital to make sure it is well looked after and that your workplace
environment is hazard-free.
Even though the nature of metal fabrication is quite dangerous, if you correctly
perform these safety precautions, you can successfully prevent injuries and boost staff
Why is it necessary to use appropriate tools in fabricating the tool box like using rubber
mallet in straightening the GI sheet instead of using a regular hammer?
It necessary to use appropriate tools, having the right tool is imperative to successful
completion of the task at hand. In addition, the right tools allow the workers to complete
their task efficiently, which affords worker opportunities to expand their range of
capabilities. Hammers and mallets may look similar, but they are used for very different
purposes. If you need to hit something gently like the GI sheet, a mallet is the best option.
A mallet can hit a work surface without leaving any marks, which is its major benefit over
a hammer. On the other hand, a hammer is really used for everything else. It can drive
nails, reshape metal, and pry things apart. It is best for everything that doesn’t require light
work. As you might imagine, this makes it a far more versatile tool. Most people should
have a few types of hammers at their disposal.
When constructing the tool box, it is vital to use proper instruments, such as a
rubber mallet to straighten the GI sheet rather than a conventional hammer, because a
mallet may hit a work surface without leaving any markings, which is its main advantage
over a hammer. Mallets are blunt implements with the purpose of striking something.
They’re made to alter the shape or look of a piece of work. They are often composed of
rubber, allowing them to be used directly on a surface without leaving markings. There are
also some wood variants, though they are less frequent. The purpose of a mallet is to make
a softer impact on the object, preventing scratching and scarring. Although hammers and
mallets have a similar appearance, they serve completely different roles. A mallet is ideal
for hitting something softly, like as smoothing the GI sheet. A mallet is the perfect tool for
chisels and similar items.