Sheet metal help??!

  1. #1
    dung0beetle's Avatar
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    Sheet metal help??!

    I have never worked with the stuff, and I found some in my mom's garage the other day, and decided to make armor with the stuff. It is galvanized steel(?) I think, (magnets stick to it like crazy) and I am kinda clueless on how to roll the edges so it doesn't cut me (again).

    Can anyone help me? I thought about just folding over the edges, but the corners are still pretty sharp. I have no tools for this, only tin snips to cut with. I know a bit about dishing, but I don't know what to do about the edges.

  2. #2
    I helped at SDCC '08 GCNgamer128's Avatar
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    Re: Sheet metal help??!

    I'd talk to Wickedbeard, he's the master at making stuff out of sheet metal.

  3. #3
    I helped at SDCC '08 Jango 5204's Avatar
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    Re: Sheet metal help??!

    must be a thin gauge if your cutting it with snips. I believe you'll need to do some compound curves to get the overall curve. Plastic would be much easier, and it'll be painted anyway.

  4. #4
    Jaster TK-1580's Avatar
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    Re: Sheet metal help??!

    Yeah Wickedbeard is the Metal Man.

  5. #5
    FettSniper's Avatar
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    Re: Sheet metal help??!

    Im thinking about making the chest armour out of sheet metal aswell so any help with this matter would be most apreciated.

    Saves you buying silver paint....

  6. #6
    Stormrider's Avatar
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    Re: Sheet metal help??!

    Depending on the guage, your going to have to hammer it into shape. Youll need a grinder or super dremel to get the burrs off the edge after you cut it. Cutting it is goign to take anything from titanium snips, to a ban saw.

    How thick is the metal your alking about? Like a street sign?

    Ordo T(cant spell the rest) makes all his stuff out of metal also, I think he does medieval blacksmithing.

  7. #7
    I helped at SDCC '08 NovallTalon's Avatar
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    Re: Sheet metal help??!

    Yes, if you want it to have the proper curves then you'll need to dish it out properly. Wickedbeard and Ordo Te'skotah are masters of the hammer =D

  8. #8
    dung0beetle's Avatar
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    Re: Sheet metal help??!

    I know how to dish, it is the edges I am stuck on. I want to roll them or fold them over or something to keep the edge from cutting and to make it look thicker.

    Something like this.

  9. #9
    Skjoldhammar's Avatar
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    Re: Sheet metal help??!

    Can send/post some pics to what you'll need to do and what tools you'll need. Currently making my third armour out of metal, Boba Fett this time. Pm me if interested

  10. #10

    Re: Sheet metal help??!

    I do not hammer anything(this will leave dents that will be extremely noticable) and I definitely do not roll the edges, as this will result in creases.I use a backing on my armor to add the thickness.
    As for the curves, I usually get every curve except the top areas of the chest armor.
    If you try to bend metal to where it does not want to bend it will crease and look terrible.You want the face of the metal to be smooth.any small creases will show through the paint.
    The compound curves are only possible if you use the thicker hard to bend metal, that you WOULD have to hammer, and that kind of work and metal, would be sooooo much more expensive, and much heavier.
    I think the curves I achieve are just fine, and you gotta remember, the metal is flexible which helps it to conform to the body more nicely.
    If you really have to have the compound curves, you would either have to learn how to hammer thick metal, or go with a different material.
    and do not use tin snips.they are terrible.Go get a pair of titanium scissors at home depot in the tool section.they are only like 7 bucks and they cut the metal just fine.As for the edges, just round off the corners a bit, and take a sanding block to dull the edges down a little.
    Hope this helps.
    Last edited by wickedbeard; Nov 23, 2007 at 9:29 AM.

  11. #11
    dung0beetle's Avatar
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    Re: Sheet metal help??!

    wickedbeard said: View Post
    I do not hammer anything(this will leave dents that will be extremely noticable) and I definitely do not roll the edges, as this will result in creases.I use a backing on my armor to add the thickness.
    As for the curves, I usually get every curve except the top areas of the chest armor.
    If you try to bend metal to where it does not want to bend it will crease and look terrible.You want the face of the metal to be smooth.any small creases will show through the paint.
    The compound curves are only possible if you use the thicker hard to bend metal, that you WOULD have to hammer, and that kind of work and metal, would be sooooo much more expensive, and much heavier.
    I think the curves I achieve are just fine, and you gotta remember, the metal is flexible which helps it to conform to the body more nicely.
    If you really have to have the compound curves, you would either have to learn how to hammer thick metal, or go with a different material.
    and do not use tin snips.they are terrible.Go get a pair of titanium scissors at home depot in the tool section.they are only like 7 bucks and they cut the metal just fine.As for the edges, just round off the corners a bit, and take a sanding block to dull the edges down a little.
    Hope this helps.
    This helps a lot, thanks!

  12. #12

    Re: Sheet metal help??!

    How do you "get" the curve??...I am looking into metal armor and want to know so I can do it myself...If not rolling and hammering, then how? And are dents a problem in a boba armor model...cause hes pretty banged up.

  13. #13

    Re: Sheet metal help??!

    1/8 inch sheet metal/steel. my brother works with it. It may be thicker than that, he says he can't roll it cause it is too thick. Could that be used. And what about using rubber along the edges or canvas, that would make it safer, plus the suit protects you from that (minus cod piece.) and these compound curves, could you weld two pieces to make that curve, similar to the top of a very wide cone. Is there a way to weld plates over the creases to make a smooth surface.(if a dent was put into this raised area, you would have some nice options for effects and such.

    Also, could you weld a bullet to the metal, like a bullet that didnt pierce the armor.

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