Stationary Panels

Tools Required: Wiss metal snips, 12" Quick-Grip Bar Clamps, Utility knife, Rubber Mallet, wood file or sandpaper

Click a picture to see a larger view.

1. 3/4" Plywood square is cut to 10-7/8" so finished panel will be about 11" square. Sheetmetal is cut to 12" x 12". Center plywood on sheetmetal, trace outline, make a mark on the plywood and sheetmetal to remember orientation - this is important if your plywood piece is not perfectly square. Cut square notch out of each corner of sheetmetal (it should be about 1/2" square). Align plywood corners with the corners of the tabs that are cut from the sheetmetal.

2. Clamp a piece of scrap wood on top of the sheetmetal so as to create a sandwich. This will keep the metal from rising off the surface of the wood during bending. Make sure the sheetmetal is properly aligned on the plywood square.

3. Score the underside of the sheetmetal along the edge of the wood where the bend will be.

4. Keeping the sheetmetal tab as flat as possible on the edge of a workbench (a 2x6 works just as good) slowly rotate the plywood so as to bend the sheetmetal around the edge.

5. Finish the corner off by lightly tapping with a rubber mallet along the edge of the bend.

6. AFTER you complete the bend, sand or file the edge of the plywood that you just wrapped the sheetmetal around. This will allow the metal to sit closer against the side of the plywood. Repeat the above to the opposite side making sure you keep the side you just bent tight against the plywood. Then, do the same with the remaining 2 sides.

7. Finished panel.

8. Repeat the above 3 times

9. Notice I have not glued anything together yet.

Return to Main Page

	1. 3/4" Plywood square is cut to 10-7/8" so finished panel will be about 11" square. Sheetmetal is cut to 12" x 12". Center plywood on sheetmetal, trace outline, make a mark on the plywood and sheetmetal to remember orientation - this is important if your plywood piece is not perfectly square. Cut square notch out of each corner of sheetmetal (it should be about 1/2" square). Align plywood corners with the corners of the tabs that are cut from the sheetmetal.
	2. Clamp a piece of scrap wood on top of the sheetmetal so as to create a sandwich. This will keep the metal from rising off the surface of the wood during bending. Make sure the sheetmetal is properly aligned on the plywood square.
	3. Score the underside of the sheetmetal along the edge of the wood where the bend will be.
	4. Keeping the sheetmetal tab as flat as possible on the edge of a workbench (a 2x6 works just as good) slowly rotate the plywood so as to bend the sheetmetal around the edge.
	5. Finish the corner off by lightly tapping with a rubber mallet along the edge of the bend.
	6. AFTER you complete the bend, sand or file the edge of the plywood that you just wrapped the sheetmetal around. This will allow the metal to sit closer against the side of the plywood. Repeat the above to the opposite side making sure you keep the side you just bent tight against the plywood. Then, do the same with the remaining 2 sides.
	7. Finished panel.
	8. Repeat the above 3 times
	9. Notice I have not glued anything together yet.