This is a video showing how to build a custom sized project box out of a thin aluminum sheet and some aluminum angle bar. The photos below will also help understand the tools and procedures I used. I will also add some links to the tools and material below the video. (My Project Box Drawings – PDF)

FYI: Here  is a website that does one-off custom project boxes. I don’t know the pricing.

Video:

Material:

• Aluminum Sheet 6 in. x 18 in. 21-Gauge
• Aluminum Flat Angle 1/2 in. x 1/2 in. x 12 in. – 1/16 in. thick
• J-B Weld 8276 KwikWeld Quick Setting Steel Reinforced Epoxy
• Rivet pack
• Self-adhesive Clear Rubber Feet
• #4 x 3/8 inch 16 count pack (no link)

Tools:

• DEWALT scroll saw
• Affordable scroll saw
• Scroll saw stand
• DEWALT hand-held bandsaw
• Affordable hand-held bandsaw
• Dewalt drill (or) better yet this
• Dewalt drill bit set
• Engineering paper
• Riveter gun
• Tin Snips Straight Left and Right Cut
• Vernier Digital Caliper
• Vernier Dial Caliper
• Air nibbler
• Air saw
• Air cut off wheel

Photo Gallery

CLICK PHOTO for gallery view and click a SECOND time for hi-resolution image. Click thumbnails on lower right and lower left of gallery to navigate gallery photos.