Fabrication: Pencil Caddy

So not technically a motorcycle-related project, however all this welding practice and metal forming skills will eventually (hopefully) be used in creating seat pans, rear sets, light mounts, and who knows... maybe a gas tank one day?

It all starts with the first fumbling steps...


Drew the pattern on this 22ga steel sheet the night before.

Getting my cart set up at the shop.

Did the big cuts on the hydraulic shear.

Turret punch the relief holes and handle screw holes.

Corner notch the small square cuts, followed by an out-of-focus shot of the Beverly shear, used to cut the little triangle next to the relief hole.

And finally, finger brake for the bends.

Normally, you'd then weld the sides together, but I learned that you can't weld 22ga at 50amps with a 1/16 electrode (it just melts the metal).  The calculators don't go lower than 1/16" for some reason, though obviously it can be done.  Figured I'd read up a little more before attempting that.

So I left the sides unwelded for now.  Added some 6mm bolts, washers, wingnuts and orange paint. Dimensions are 9" long x 4" wide x 1 1/2" tall.