The first step in building a metal box is to notch the corners.
To kick off Metallic Moments, our series on metal working and fabricating, let’s take a look at one of the basic techniques in metal work – making square corners. Jim Koper is a master metal worker at Storm Copper and he has a passion for custom work that lets him exercise his creative nature.
“The first step to making a metal box is notching out the corners so they’ll meet at the right angle when you bend them together. While you can bend sheet metal up to 16 gauge by hand, using a piece of wood and a mallet, it is a very difficult and tedious process. And for 18 gauge you’d really have to struggle with it. So, once I’ve notched all four corners, I’ll be using a box and pan handbrake to bend the sides,” he said.
Koper went on to explain that a sheet metal handbrake bends sheet metal by using a hinged clamping bar to hold the metal down against the bed. A hinged bending “leaf” is lifted to fold the metal around the fulcrum point of the clamping bar to the desired angle. However, with a standard hand brake can only bend three sides. A box and pan brake is designed to prevent the metal from hitting against the clamping bar when the 3rd and 4th sides are being bent. The clamping bar on a box and pan handbrake is divided up into many assemblies called “fingers” which can be removed at each end of the box.
Once the corners are formed, Koper uses a TIG welder to seal the two pieces of each corner together, and then he grinds away the excess bead to dress up the seam and make the corners into a smooth joint. Tungsten inert gas (TIG) welding, is an arc welding process that uses a nonconsumable tungsten electrode to weld two pieces of metal together. During the bonding process, the area to be welded is protected from atmospheric contamination by a shielding gas and a filler metal is normally used. The shielding gas is usually an inert gas such as argon.
“The twisted handles I put on top are made from ¼” square stock that has been heated to 1200 degrees to anneal or soften the copper. Then once it cools, I put one end in a vice and use an adjustable wrench to twist it, and then make the curve by bending it over a piece of pipe,” he added.
The next step is to pickle the whole box in muriatic acid to remove the scale that develops from welding, and then it’s just hand polishing to develop the final finish. While admiring his work, Koper offers a bit of encouragement to those who would like to duplicate this box. “Boxes aren’t that difficult to make, just basic hand work.”
This beautiful copper box was fabricated using .024 gauge decorative copper sheet. Contact our friendly customers service staff at 1-888-334-2177, or order online at quickshipmetals.com.
When Chris got a chance to purchase the boat of his dreams he didn’t hesitate, even though he knew he’d have to update it a bit. The dash was faded from the sun and being a metal worker he knew just what he wanted to do. With two pieces of brushed stainless and the purchase of some custom bits to drill the holes, this 18′ 1985 Master Craft Competition ski boat is just about ready for the water and a summer full of skiing! One thing for sure, with the brushed stainless steel, there won’t be any problem with the dash fading now. Thanks to the folks at Quick Ship Metal for a great price on the metal.
Need some stainless steel? Here’s the good stuff at a great price!
As a collective society we tend to think of ourselves as very sophisticated, more refined and better educated than our ancestors. To some degree that may be true. After all we have the iPod and the iPhone, and some of us can actually use them.
Much of our national pride in anchored to technology, but just a few years ago only one in 10 homes in this country had a telephone. These wooden boxes with gleaming brass bells mounted prominently above the mouthpiece were considered a luxury. They were mounted permanently on the wall, connected to the world with small copper wires.
Politicians like to take credit for the fact that our nation put a man on the moon, but I can remember standing outside in our front yard, looking up in the dark sky, as the Russian Sputnik passed overhead. Sunlight reflecting off of its metal surfaces glowed brightly as neighbors remarked that people have lost touch with reality.
Sadly, they were right, but not for the reasons they were considering. In our rush to adapt new technologies, we have lost the connection to and awareness of things that were common knowledge for elementary students only a generation past.
For example, on a really cold winter’s day, people often say, “It’s cold enough to freeze the balls off of a brass monkey,” snickering at the visual image and sexual connotation that remark conjures up. But, historically, the term had nothing to do with the animal, nor its anatomy. In the early history of the world’s navies, power was projected with a fleet of wooden warships bristling with cannons and the will to use them. In battle, it was critical to have a ready supply of cannon balls placed in strategic positions on the gun deck. To keep them in place, they were stacked on a metal plate with indentations to keep them from rolling away. Starting with a base of sixteen, these square-based pyramids could hold a supply of 30 cannonballs in a small area next to each cannon. These monkeys were made of brass, so they wouldn’t rust in the harsh environment of salt and sea. Unfortunately, one thing the navy didn’t consider is brass contracts faster than steel. When it was really cold, the brass contracted so much it would literally squeeze the steel cannon balls out of the rack and they would roll about on the deck, while sailors scampered about to gather them.
And what about the term, right-hand man? We use it often, and although there is a general understanding of the meaning, the origin and importance of the term has been lost to a population with a disdain for history. During this same period in time, a gentleman defended himself with a blade of cold steal that he carried on his left side. If an enemy wanted to do you harm, all they had to do was win your confidence to the point that you allowed them to walk on your right side. When an assailant approached, the deceiver only had to do keep you from drawing your sword by restricting the motion of your right hand, and in the flash of a blade of steel you were done in. Therefore, only your most trusted friend was allowed to walk on your right side, and he became known as a right-hand man. Unfortunately, as Caesar found out the hard way, right-hand men could be bought for a price or the promise of power.
Only a few years back, every community had a blacksmith. Although scarce today, there are still many men practicing this time-honored craft. The term “smith” means they make things, or are craftsmen, and the “black” part of “blacksmith,” means that he is someone who works in “black” metal — iron — as opposed to the “white” metals such as tin or silver. While Hollywood has popularized the image of a man pounding out horseshoes in the old west, these craftsmen were important because they created many things that were necessary for our daily existence. From plowshare to wagon wheel, hinge and hearth as well as the cooking vessels than hung on the hearth, if it was made of iron, it came from the village blacksmith’s forge.
While we may have lost the awareness of these men and their skilled craftsmanship, we have not lost our affection for things of metal. In our homes and offices, we surround ourselves with metal décor and accent our rooms with stainless steel, copper and brass. Sure, it’s serviceable, durable and beautiful, but I think the reason we love metal around us runs deeper than we might imagine. There is a sense of strength and permanence in the touch of metal that connects us back to a simpler time when things were made to last.
In the coming weeks, I’m going to share an occasional “metalic moment” with you, and take a look at the techniques used to work with metal. Who knows, you might have the heart of a blacksmith waiting to be discovered.
In the meantime, if you’re considering a purchase of metal for a project, please evaluate the wide variety of metals offered at quickshipMetals.com
I am writing to acknowledge the positive experience I had with recent purchase from ‘QuickShipMetals’ (Storm Mfg). The sales personnel (Jon) was knowledgeable and made the internet ordering process painless. The cut dimensions and perfectly orthogonal angles made the fit so perfect I did not need to use the edge trim (thanks to the employees in the shear room). My expectations were exceeded when a UPS truck arrived to pick up the extra trim for return to factory (I had expected to take it to UPS – thank you Jon).
The use of stainless steel in the oven hearth provides a moisture tight area that is easy to clean and superior light reflection while cooking. It also enabled us to have wider spice racks due to the thin backerboard required relative to tile. Attached are some photos of the finished product. The camera flash makes for a poor photo but the steel blends well with the stove top.
Best Regards, Dale K
Copper comes in many forms and thicknesses. Copper sheet is thick, ridged and can be difficult to bend and cut by hand, but it is strong and durable. Copper flashing is flexible and has a soft temper which means it can be more easily formed and cut by hand. Although used primarily in roofing applications, copper flashing has many craft and decorating uses. Copper foil is the thinnest and most flexible copper sheeting available. We also stock a good selection of aluminum and stainless crafting foils. The flexibility and durability varies with the specific thickness of the foil used.
Selecting the right thickness and flexibility of copper foil or copper sheeting for an art project is not difficult once you have some comparative information to go by. Listed below is a brief explanation of some of the cutting and forming characteristics of copper foil and copper sheeting to consider when determining the correct thickness of material for your requirements.
.001″ copper foil - Can tear with fingers, cuts perfectly with normal scissors, really feels like aluminum foil that you would find in your kitchen cabinet.
.003″ copper foil – Can not tear with fingers, cuts perfectly with normal scissors, easily shaped by hand.
.005″ copper foil - Cuts perfectly with normal scissors, shaped easily by hand, retains shape but still fairly flimsy.
.010″ copper foil - Can still be cut with scissors, shaped easily by hand, can make 90 degree bends by hand, retains shape well.
.0216″ copper coil - Need metal snips to cut, can be bent by hand, 90 degree bends by hand are difficult.
If you’re still not sure what thickness you need? Just give us a call at 1-888-334-2177 and we will be glad to help you out.
If you’re impressed with size, take a look at TacomaCopper.com’s “Monster-The 15 Kilogram Polished” bar.
While precious metals like gold and silver have always been used as a hedge against bets, excuse me, investments in the stock market, the latest marketing ploy has to have some of the promoters of this concept making their sales pitch with tongue in cheek. Clever metal marketers are now pushing Copper Bullion as the next bullish metal for rich returns. Copper bullion bars, ingots, coins, and even vintage pennies are emerging as a brand new niche with precious metals investors and collectors.
Over the years, as the investment metals’ market broadened, platinum and palladium found their way into the mix. Interestingly enough, today platinum (in the range of $1,500) commands a higher price than gold, which has fallen slightly from its recent record price of $1,200 per ounce. Notice in that last sentence I said “today”, for one thing that is always a certainty in any market is change. Depending on which expert you choose to listen to, the big four are headed to double, triple or even quadruple in the coming months.
If you don’t have that kind of money to sink into metal investments, but you still want to play the game, take a look at copper. You can buy a troy ounce of copper for around a dollar, and considering the value of our dollar that’s probably a better use for it. The following information is not an endorsement of any web site, their services, or the financial viability of investing in copper. It is simply a survey of what is happening in this emerging metal market concept.
BullionCopper.com is selling copper in one pound bars, with the same type of artwork that makes other metals so appealing. You can even custom design your own bar, or buy one of the traditional looks such as the Morgan Incuse 3D Pressed Image, the American eagle or the Liberty Bell.
If you’re impressed with size, take a look at TacomaCopper.com’s “Monster-The 15 Kilogram Polished” bar. This company declares their site to be “Home to the Finest Copper Bullion Products.” And perhaps there is something that claim, since all of the product photos feature people holding highly polished bars with white gloves. Presumably you will need your own pair of white gloves once the product arrives, so you can so it off these sanded and highly polished bars to your friends in the appropriate method.
Unadorned bullion bars are another way to invest in copper. Jetco Minting, a U. S. mining company, is selling a variety of copper bullion bars on Ebay, the popular online auction site. If you’re looking for one-stop shopping, check out The Copper Cave. It’s one of the newest copper ingot stores on the WWW. They offer copper bullion bars from all of the major copper bullion mints, so you can comparison shop without all the clicking from one site to another. Certainly there are others, for this is not meant to be an exhaustive presentation on every copper investment available, just a lighthearted look at the curious world of investing, speculation and gambling.
Speaking of gambling or sporting speculation in its purist form, if you bet on the Colts in this weekend’s Superbowl, perhaps a bet on copper would have moved you closer to an investment trophy of your own! Copper, it’s an amazing metal in so many ways. Think about it!
Sean Alton creates beautiful metal art using copper and various enameling techniques. “The majority of my work is in copper. You can’t beat it,” Alston said.
Just watching the video will make you want to give it a try. Call our customer service staff to order your copper when you’re ready. 1-888-334-2177.
This video demonstrates a very easy technique for etching copper, and the purpose of this post is not to endorse the product but to share the technique. Copper etching is a great technique for creating beautiful pieces of metal art that stand alone, or can be used as a part of other projects.
After 12 years as a Customer Service Call Center Manager, Misti Wade knows what it takes to take care of business. “I’ve been at this a long time, and seen just about everything. What I’ve learned over the years is that you don’t have to know everything you just have to know where to find the answer. I do my best to provide the best service possible by using all of the resources I have available to me,” she said.
“When I started here, it took me about four months to get through a day without thinking my hair was on fire. I knew people and customer service from top to bottom, but I’d never been involved in a manufacturing environment. This job opened up a whole new world to me,” she explained.
Misti handles mostly distribution copper in orders over 500 pounds, mainly for construction sites and larger companies. “Part of the training here is to spend time in the shop area, and that was a big help. I got to work with rolled foil and shipping. I learned a lot, and ask for more opportunities when time permits. I want to learn as much as possible, so I can do a better job of helping my customers,” she added.
“Misti’s best friend is her 11-year-old son. She likes to work out and mountain bike, but is quick to add that she doesn’t do trails that are too difficult. “I’m prone to accidents. I fall a lot, get bruises and cuts,” she laughed. “We’ve got some beautiful trails around here, which makes it a nice place to live and work. I’ve worked in a couple of places where the best day would not have been as good as the worst day I’ve had here at Storm Copper. I love this place. I’ve never worked for a company as good to their employees as this. I’ve never had a bad day here,” she smiled.
Dana Smith likes to keep busy, and with a full-time job, two children who need to be transported to weekly activities and a passion for quilting, staying busy is not a problem. Dana has 12 years experience in customer service; 10 in the banking business and the last two on the customer service team at quickshipMetals.com.
A perfect day for her would involve non-stop action that culminates in all the Internet and phone orders getting down to the shop by the 2 p.m. deadline, shipped out on time and the shop crew not having to work late. At QSM, orders that come in by 2 p.m. are shipped out the same day, and sometimes that presents challenges. Dana’s responsibilities include managing the order flow to the shop, making sure items that are low get restocked and keeping QSM customers happy.
“I have a gift for talking,” she said with a chuckle. “In customer service, there’s always going to be one customer that you can’t make happy, but I haven’t met that one here yet here. I love talking to customers and helping solve their problems and the staff here is so much fun to be around I love my job.”
When she’s not at her desk talking with customers, a needle and thread are balm for her soul. She meets monthly with a group of ladies and finds solace in creating beautiful quilts. The delicate, intricate stitching required may seem difficult and even daunting to others, but for her it’s a form of therapy that is both relaxing and rewarding. Perhaps it is this ability to patiently piece together various colors and textures of fabric in an artistic presentation that enables her to be so successful with the many varied personalities and challenges she deals with each day at QSM.
When cares are stitched together properly, they seldom unravel.
