Help needed - Sheet metal shears and brake

[Kevin Doe]

Anyone have access to a sheet metal brake and shears that could help me build a toolbox.

I have it all designed in CAD, and 2D flat layouts all ready to be cut out and bent up. I have it all planned otu and just need some help with getting it made up. I just need it sheared and bent up. I will be doing the welding.

I will need a shear that can fit in a 60" wide sheet. I'll also need someone that has a sheet metal brake that has a 1/8" or close radius die. It will need to have a width capability of 55". The material will be 1/8" aluminum, 3003.

I've been through two people that said they'd help me out but ended up falling through when I needed. Here is my design. Can anyone help me out? I pay with actual money, or can return the favor in welding services.

Here is my design. This is for my tire trailer tool box.

Overall view
http://i93.photobucket.com/albums/l55/Kevin_Doe/RX-7/AssemblyView.jpg

Bottom Corner
http://i93.photobucket.com/albums/l55/Kevin_Doe/RX-7/AssemblyView3.jpg

Lid corner
http://i93.photobucket.com/albums/l55/Kevin_Doe/RX-7/LidView.jpg

View of how lid will sit on the base. I'll have a seal in there.
http://i93.photobucket.com/albums/l55/Kevin_Doe/RX-7/AssemblyView2.jpg

Here are the layouts with dimensions.
Main base.
http://i93.photobucket.com/albums/l55/Kevin_Doe/RX-7/BottomLayout.jpg

Sides of base.
http://i93.photobucket.com/albums/l55/Kevin_Doe/RX-7/BottomSideLayout.jpg

Main lid.
http://i93.photobucket.com/albums/l55/Kevin_Doe/RX-7/LidLayout.jpg

Sides of lid.
http://i93.photobucket.com/albums/l55/Kevin_Doe/RX-7/LidSideLayout.jpg

[tcorns]

i wish i was still at the airport. i could have helped you out!
why 1/8 inch aluminum? is that not a bit on the large side? unless you go with -0 material and heat treat it i think you are going to have some big issues with an 1/8 inch radius. even if you so go 90 degrees to the grain and polish the crap out of it. what cad program are you using? curious because i don't see any account for bend allowance or setbacks. so if you were to cut all of your parts before bending, your sides would not match. let me know if i need to explain some more on that. not trying to start anything just don't want to see anyone waste money on something.
just about all of the sheetmetal guys that i know in the aviation industry build there own tote trays/small tool boxes. mine was 2024-t3 .032 with a 1/8 radius. it held up just fine until i got rid of it.
sorry if this is out of line!

trev

[Kevin Doe]

I had a guy use inventor to draw it up, I thought he took in acount for bend allowances, although I'll have to verify. I was planning on 1/8" just because its readily available. I could go with something thinner for sure.

[tcorns]

could be a fun welding project. we always riveted ours together. had one guy make one out of titanium. man it was wicked when he was done and had it polished up. if you go with something like .032 t3 then you could do most of the bends on a bench with some clamps and wood.

[Kevin Doe]

Did you see the dimensions, its 55" x 24" x ~18" tall. 0.032 would be like a tin can for sure.

[tcorns]

i think that you would be surprised at what happens to metal when you start adding strength to it. most commercial airliners have skin with a thickness of .032 to .040 with very minimal support. still no way that i would run .125, not to mention that you will not be able to bend against the grain on the long side. which will make it prone to cracking while bending.