Emilie Meyer
Sheet metal is a versatile material with a wide range of applications, from cookware to condensate drain pans. Creating a sheet metal under pan requires some basic knowledge of metalworking techniques such as cutting, bending, and welding or soldering. The process begins with measuring and cutting the sheet metal to the required size, allowing extra room for bending and forming the corners. Notching the corners enables the sides of the pan to be bent upwards, and special equipment like sheet metal brakes or power tools can aid in achieving precise bends. Finally, welding or soldering the corners ensures a watertight seal. While sheet metal offers flexibility in crafting custom pans, it's important to consider the potential issues of metal expansion and warping when exposed to heat, as well as the need for proper safety equipment when working with power tools and metal.
| Characteristics | Values |
|---|---|
| Purpose | To prevent condensate water from dripping into areas where it is not desired |
| Uses | Home air conditioning systems, under vertical duct risers, under water heaters in attics or crawl spaces |
| Requirements | Basic knowledge of cutting and bending sheet metal, soldering or welding to make corners water-tight |
| Process | Measure and cut sheet metal, notch corners, bend sides, solder or weld corners, drill hole for drain pipe connection |
| Cutting Tools | Air-powered nibbler, spot weld cutters, air-powered body saws, abrasive cut-off wheel, plasma cutter, tin snips, sawzall, air chisel |
| Warping | Thin pans may "pop" due to temperature differences and expansion of metal; thicker pans are less likely to warp |
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What You'll Learn
Cutting sheet metal
Sheet metal is made from different materials and comes in various thicknesses, known as gauges. The higher the gauge number, the thinner the metal. Thicker sheet metals tend to be more expensive and often require power tools for cutting. Softer metals such as copper, aluminium, brass, and cold-rolled steel can be cut using tin snips.
To cut sheet metal, it is important to wear work gloves and eye protection to avoid injury and protect yourself from flying metal shards. Mark the sheet metal where you want to cut it, using a carbide-tipped scribe, pencil, or marker. Use a stable bench or table to support your sheet metal. Hold the sheet over the edge or put two 2x4s underneath the metal and clamp it down. Use a carbide drill bit to drill a hole in the metal, large enough for the bottom blade of the tin snips to fit into. Tin snips have different coloured handles, each serving a specific purpose. Green handles are designed to cut in the right direction, red handles are for cutting in the left direction, and yellow handles are used to cut straight lines.
For thicker sheet metals, use a stick wax or another lubricant to assist in cutting. Lubricant ensures blade longevity but can make the process messier. As you reach the end of the cut, stabilize the side with the straight edge so it doesn’t bend under the weight. Once the cut is complete, you can release the clamps from the sheet metal and file the edge smooth. Check and empty the shop vac for fires.
A metal cut-off disc or a diamond blade disc can be used to cut metal rebar, steel bars, stainless steel, cast iron, and angle iron. A Dremel metal cut-off wheel can also be used to cut most metals, but it is important to refer to the packaging for its specific capabilities. Power tools such as an angle grinder, band saw, rotary tool, circular saw, or chop saw can also be used to cut thicker sheet metals.
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Bending sheet metal
When bending sheet metal, there are several accessible methods and tools available. One approach is to use a sheet metal brake, a simple and long-standing technique that remains widely used. However, it's important to select the right type of brake for the thickness of the material, as some brakes have limitations in terms of material gauge and width. Additionally, clamping the metal in a vise and hammering it can be effective, but it requires patience and good technique to avoid waviness and dents.
Another method is to use a CNC press brake, which can be useful for bending thicker materials like 16-gauge steel. However, it's important to note that bending capabilities may vary, and some bends might not be offered by certain services. Bending can also add processing time to your order, and it may leave cosmetic die marks on the parts. These marks can be removed with a DA orbital sander, and powder coating can be applied for a protective and aesthetic finish.
For smaller projects or bending little parts, there are DIY options available. One suggestion is to use angle iron to create a metal brake. Additionally, heating a strip to red-hot with an acetylene torch and then bending it could be an option, although maintaining a narrow heated zone may be challenging. It is recommended to refer to online resources and tutorials for specific techniques and tools to achieve successful sheet metal bending.
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Soldering sheet metal
Preparation:
Before beginning the soldering process, it is important to ensure that the metal surfaces to be joined are clean and free of any contaminants. This includes removing any grease or debris with a degreaser and ensuring that the flux, which aids in the soldering process, is also uncontaminated.
Fitting the Pieces:
The two metal pieces should fit together with minimal gaps. This can be achieved by filing the pieces until they sit flush against each other. If you are soldering a sphere or dome to a flat sheet, consider drilling a small hole in the sheet to help disperse the heat and prevent warping.
Soldering Techniques:
There are several techniques for soldering sheet metal, depending on the specific application. Here are some common methods:
- Wire Ends to Sheet: You can melt solder onto the end of a wire and reflux both the wire and the desired spot on the sheet. Hold the wire end to the sheet and apply heat with a torch until the solder flows and joins the pieces.
- Drilled Hole Method: Drill a hole in the sheet metal that is the same diameter as the wire. Pass the wire through the hole, apply flux and solder, then heat with a torch until the solder flows.
- Lengthwise or Parallel Joins: When soldering a wire lengthwise or parallel to the sheet, secure the wire with binding wire. Apply flux to both pieces and place small pieces of solder along the joint. Dry the flux and apply heat until the solder flows and creates a strong joint.
- Bezel to Sheet: Place the bezel and sheet together, ensuring a tight fit. Set up the bezel on a tripod and screen to heat it from below. Place solder along the inside edge of the bezel or between the bezel and sheet. Hold the bezel down with a soldering pick and apply heat until the solder flows.
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Welding sheet metal
Welding is a process that joins metal parts together. It is a common method for creating connections between metal objects. Sheet metal welding is a complex process that requires various techniques.
There are two main types of welders used for sheet metal welding: MIG (Metal Inert Gas) welders and TIG (Tungsten Inert Gas) welders. MIG welders are a popular choice for sheet metal welding due to their ease of use and versatility. They use a continuously fed consumable wire electrode and an inert gas shielding to protect the weld from contamination. If you're using a MIG welder, you'll need a gas cylinder filled with a shielding gas, typically a mixture of argon and carbon dioxide. When using MIG welding, it is best to use 0.023, 0.024, and 0.030 in MIG solid wires for sheet metal. Avoid a 100% CO2 shielding gas, as it amplifies penetration, leading to burn-through. Instead, use a mixture of 75% argon and 25% carbon dioxide. Push your weld instead of pulling, as pulling will give you more penetration than is needed.
TIG welders use a non-consumable tungsten electrode and an inert gas shielding. They offer more precise control over the weld but require more skill to operate. TIG welding works well for welding thin sheet metal, especially with a pulsed TIG mode. Pulsed TIG provides an arc that fluctuates amperage output between two set values up to 500 times per second, allowing for excellent heat control. When using TIG welding, grind the tungsten tip to a sharp point to weld steel and use either ER70S-2 filler metal or a silicon bronze rod. Avoid helium-argon shielding gas mixtures, and stick to pure argon shielding gas.
Before you begin welding, ensure that you have gathered your equipment and followed all safety practices. Clean the weld area thoroughly with a wire brush or grinder to remove any dirt, grease, paint, or rust. Decide on your joint type (butt joint, lap joint, etc.) and prepare the metal edges accordingly.
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Tools for cutting sheet metal
Sheet metal cutting tools are essential for any metal fabrication project, including creating a frying pan from sheet metal. Here are some of the tools you can use to cut sheet metal:
Bandsaw
A bandsaw is a power tool that uses a continuous band of toothed metal to cut through materials. It is suitable for cutting various materials, including wood, metal, and plastic. When working with sheet metal, a bandsaw can make straight or curved cuts, depending on the user's requirements.
Grinder
A grinder, also known as a disc grinder or angle grinder, is a handheld power tool that uses an abrasive disc to cut, grind, or polish materials. It is suitable for cutting sheet metal and can be used to make straight cuts or shape the metal by grinding off small sections at a time.
Metal Sheet Brakes
Metal sheet brakes, also known as box and pan folders, are manual machines used for bending and forming sheet metal. While they do not directly cut the metal, they are essential for creating the desired shape of your sheet metal pan. These machines have a simple design with few parts, but they remain widely used in fabrication workshops and engineering departments due to their effectiveness and durability.
Sheet Metal Nibbler
A sheet metal nibbler is a tool used to cut through sheet metal by removing small bits of material with a punching motion. It can create precise and tight curves, making it ideal for intricate cuts that other tools might struggle with.
Power Shears
Power shears, or tin snips, are scissor-like tools designed specifically for cutting sheet metal. They are available in various sizes and blade configurations, allowing for straight or curved cuts. Power shears are a handheld option that provides good control over the cutting process.
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Frequently asked questions
Sheet metal under pans have a variety of uses, but their main purpose is to prevent condensate water from dripping into areas where it is not desired. They are used in home air conditioning systems, under vertical duct risers, and even under water heaters in attics or crawl spaces.
It is recommended to use raw metal designed for cookware, such as raw carbon steel or stainless steel. Ensure that the stainless steel is food-grade to avoid potential toxicity issues. Avoid using materials like soda cans or cooking cans, as they are lined with plastics that can leech into food when heated.
Various tools can be used to cut sheet metal, depending on the specific application and the type of cuts required. Some common tools include air-powered nibblers, plasma cutters, spot weld cutters, air-powered body saws, abrasive cut-off wheels, tin snips, and sawzalls.
Warping is a common issue with metal pans due to the expansion and contraction of the metal during heating and cooling. To prevent warping, opt for thicker pans, such as those used in restaurants, as they tend to be more durable and less susceptible to warping.
To make a sheet metal under pan water-tight, you need to solder or weld the corners. Soldering is generally preferred for light-gauge pans, while welding is more suitable for heavier-gauge pans. Ensure that all corners are square before soldering or welding to achieve a tight seal.
