How to Build a Metal Drawer Box (Step By Step Tutorial)

In these instructions, I will share my experience building this metal drawer box. This drawer is functional and unique, providing information on metalworking that you can apply to different projects and sizes. I will teach you how to build a metal drawer box in 10 simple steps.

What is A Metal Drawer Box?

A metal drawer box is a heavy storage box often made from steel or any other metal. It is ideal for use where people require extra strength and items must be stored for a long time, such as in industries, workshops, or even homes.

Made to withstand heavy use and provide secure storage, a metal drawer box usually features the following:

● Strong Construction: Built from sheet metal, often steel, for structural integrity and resilience.

● Smooth Operation: Equipped with drawer slides or runners for easy opening and closing.

● Customizable Design: This can be tailored to fit specific dimensions and mounting requirements.

● Versatile Applications: Used in welding carts, tool cabinets, workbenches, and more, offering organized storage solutions for tools, parts, and equipment.

How to Build a Metal Drawer Box | Steps To Built a Metal Drawer Box

So, how to build a metal drawer box? Building a metal drawer box involves precise steps to create a sturdy storage solution, from cutting and folding steel sheets to securing slides.

Step 1: Collect Tools and Parts

For this project, it's essential to gather the necessary tools and materials before starting:

● Clamps: Vise grips are recommended for holding metal pieces securely during cutting and assembly.

● Steel Sheet: Choose a suitable gauge and size for your drawer. I opted for a 12"24" sheet, but adjust according to your needs.

● Angle Iron: This will serve as the framework for mounting the drawer.

● Flat Bar: Used to attach sliders and adjust drawer height if necessary.

● Tap and Die Set: Includes M8x32 machine screws for assembling parts and 1/4"x20 bolts for structural support.

● Drill Bits: Use a 5/32" bit for smaller holes and a 7/32" bit for larger holes.

● Drill: Essential for creating holes in metal components.

● Screwdriver: For driving screws into place.

● Box of Screws: Various sizes may be needed depending on your assembly choices.

● Tools for Cutting Metal: Tools like an angle grinder or metal shears may be necessary, depending on your setup.

● Optional Tools: Consider using a welder and angle grinder for more secure and customized assembly.

Step 2: Cutting and Folding Your Box

Begin by marking and cutting out the four corners of your steel sheet. The dimensions will vary based on your intended drawer size and mounting space.

● Marking and Cutting: Use a scribe or marker to outline the corners before cutting with metal shears or an angle grinder.

● Precision Cutting: Ensure straight cuts to facilitate accurate folding and assembly later.

Step 3: Metal Brake and Folding

Given the absence of a traditional metal brake, create a makeshift version using available materials.

● Improvised Metal Brake: Clamp a straight metal or wooden scrap along the edge of your workbench. This makeshift brake helps in achieving clean and precise folds.

● Folding Technique: Secure another scrap along the edge of the metal sheet to assist in bending. Fold each edge to approximately 90 degrees, ensuring uniformity across all sides.

Step 4: Remaining Sides

The remaining sides require careful handling to maintain structural integrity and ensure a snug fit.

● Finding Suitable Sections: Identify smaller steel sections or use available scraps to match the required lengths.

● Clamping and Bending: Use clamps or vise grips to secure the metal sheet in place while bending the sides to form the box shape.

● Ensuring Consistency: Verify that all bends are uniform to avoid misalignment during assembly.

Step 5: Connecting the Corners

Connecting corners effectively reinforces the drawer box and provides stability, depending on your choice of assembly method.

● Welding Option: If you have a welder, welding the corners enhances durability. Weld the corners securely and grind down any excess material for a smooth finish.

○ Marking and Drilling Holes: Mark the center line on each scrap piece used for corners. Drill four holes per corner, evenly spaced, to facilitate secure attachment.

○ Alternative to Welding: For those without access to welding equipment, consider using rivets instead. Ensure the rivets are suitable for metal thickness to maintain structural integrity.

● Finishing Touches: After securing corners, smooth out rough edges using a grinding wheel or file to prevent injuries and improve aesthetics.

Step 6: Attaching the Slides

Customizing drawer slides ensures smooth operation and compatibility with your welding cart or chosen surface.

● Design Considerations: Determine the optimal placement for drawer slides underneath the welding cart or chosen surface.

● Marking and Drilling Holes: Mark three mounting points for each slide on the angle steel. You should use a drill bit that is suitable for the size of your machine screws (typically M8).

● Securing Slides: Attach each slide using machine screws through pre-drilled holes. Ensure slides are level and aligned for smooth drawer operation.

● Optional Adjustments: If necessary, use a flat bar to adjust the drawer's height. Mark, drill, tap, and secure the flat bar to accommodate specific height requirements.

Step 7: Avoid Common Mistakes!

Learn from my experience to avoid common pitfalls and ensure a smoother assembly process.

● Slide Compatibility: Double-check that each slide is custom-fit for its designated side to prevent unnecessary adjustments later.

● Consistency in Design: Avoid making identical slides for both sides, as this oversight can lead to operational issues and require rework.

Step 8: Securing the Box

Secure the drawer box firmly to the slides or chosen mounting surface to reinforce it and ensure lasting durability.

● Drilling for Strength: Drill additional holes along each side of the box for added stability. While two holes suffice, four holes per side increase overall strength.

● Fastening Options: Use M8 machine screws or rivets to secure the drawer box firmly to the slides. Consider rivets if you opted against using a flat bar to lower the drawer height.

Step 9: Drilling and Tapping More Holes

Prepare the drawer for attachment to its intended surface, ensuring a secure fit.

● Mounting Preparation: Drill four corner holes into the angle iron for precise alignment.

● Transferring Marks: Transfer these marks onto the mounting surface, ensuring accurate placement for seamless installation.

● Securing Method: Use a 1/4"x20 tap to thread holes in the mounting surface, or choose self-tapping screws for easier installation.

Step 10: Attach the Drawer

Complete the assembly by attaching the drawer securely to the mounting surface.

● Final Installation: Align the pre-drilled holes on the drawer with those on the mounting surface.

● Securing Hardware: Use appropriate fasteners to secure the drawer firmly, ensuring stability and smooth operation.

Safety Guide

Safety was paramount when I built a metal drawer box for my welding cart. Here's how I ensured a safe working environment:

● Secure Workpieces: I securely fastened metal sheets before cutting or drilling using clamps and vise grips. This prevented any unexpected movement and kept my hands safe from slips.

● Handle Tools with Care: I took the time to understand and safely use tools like drills, grinders, and welders. This familiarity ensured efficient work without risking injury.

● Mind Electrical Hazards: I paid close attention to cords and plugs to avoid potential electric shocks and ensured all connections were secure when using power tools.

● Stay Safe Around Heat: Working with welding equipment meant being cautious around hot surfaces. This preparedness ensured I could respond effectively to any accidents or injuries.

These safety practices helped me complete my metal drawer box project successfully and ensured a secure and enjoyable DIY experience. Safety is fundamental in every workshop endeavor.

Conclusion

Building a metal drawer box requires meticulous planning and precise execution. By following these detailed steps and leveraging appropriate tools and raw materials, you can create a customized storage solution tailored to your needs.

Whether enhancing a welding cart or organizing workshop tools, this project offers practical insights into metalworking techniques applicable across various DIY projects. Happy building! Hope you know how to build a metal drawer box.