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.

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.

By Frank Ross

In addition to copper’s amazing properties, it is also an effective tool for controlling other bothersome pests such as mosquitoes and slugs.

Photo by Robin Rosetta.

Photo by Robin Rosetta.

People living in damp climates, such as the Pacific Northwest, are often plagued with slimy, creeping, plant-eating slugs. There are about 40 different kinds of slugs living in the U.S., but only about half of them are considered pests. The good news is, you don’t have to know what kind of slug you have because the methods of control are the same for all of them.

Slugs have voracious appetites and can destroy a garden over night if enough of them slither in. While chemicals are available, a far safer method of controlling slugs is to set up barriers of copper strips. Some people even use a line of copper pennies to establish a barrier that snails can’t cross. Although these coins current value is probably greater for their recycled metal, strips of copper sheeting are far easier to work with and less likely to be disturbed.

According to University of Idaho extension entomologist Bob Stoltz, there is an environmentally friendly method that repels slugs and doesn’t put harmful chemicals into the soil. Barriers made of strips of copper sheeting work very well because copper causes a reaction with the slug’s mucous that is similar to an electric shock, and that is what repels the slugs.

Making your own copper barriers is simple. Cut the copper sheeting into strips at least two or three inches wide and place them along the edge of your garden’s border, pressing the metal down approximately one inch into the soil. Just make sure you’ve removed all of the slugs from the area you are encircling, or you’ll be keeping the slugs inside instead of out.

You can also use copper strips to prevent slugs from climbing the trunks of trees. If you attach the strips at the end using paperclips instead of a permanent seal, the copper strips will be able to expand as the tree grows and the trunk expands.

The all too familiar droning hum of an approaching mosquito is standard fare during summer months, and in warmer climates there really is no down time for this deadly driller. That’s right; a mosquito’s bite can be far more serious than an itching whelp.

These pesky insects may be small, but each year their bite spreads diseases to more than 700 million people worldwide. Mosquito borne diseases include malaria, and viruses such as dengue, encephalitis and yellow fever. And, don’t forget about heartworms in pets.

Copper can’t help you once these bugs are airborne, but the best method of killing mosquitoes is when they’re in the early stages of development. Mosquitoes deposit their larvae in standing water. Without water they can’t reproduce, so the first line of defense is to make sure there are no reservoirs of standing water around your home. It doesn’t have to be much water either, water in the bottoms of planters or birdbaths are common sources for breeding bugs. The best option is to have no standing water, but in areas where it rains a lot this becomes a weekly if not daily task.

A better solution is to take copper scraps and drop them into areas that hold water. Copper leeches into the water and the copper solution is toxic to mosquito larva. A solution of copper water will kill mosquito larva before they can mature. Before you start sprinkling copper scraps into water, remember it is toxic to tropical fish and invertebrates as well, but if your water has tropical fish in it, they should be eating the mosquito larvae.

You may have to do some experimenting to determine how much copper to put into the various places where you need to establish mosquito control, but it doesn’t take much. Start out with a few short pieces of copper tubing or strips of copper sheeting and come back in a few days to see if you have little wiggling larvae in your water. If so, just add a little more copper.

For controlling insects, other than mosquitoes and slugs, copper is still effective. Simply place the insect between two pieces of copper and press hard!

For more information on slugs and gardening issues, check out the Oregon State University Web site.

And, for all your copper sheeting needs, contact the staff at quickshipMetals.com

By Chris Granger

Imagine this: You’re about to build yourself a nice fence that’s about twenty-five posts long and you decide to both decorate and protect it from natural rotting with some copper post caps. However, when you go to the store, you realize that at five bucks a cap, this project suddenly skyrockets in expense! Why not save yourself some money and create these easy-to-make copper sheet caps on your own?Copper cap

To start, you’ll need a scrap piece of 4 x 4 fence post (or 6 x 6) about three feet long, a circular saw to create the form on the top of the scrap post, a wooden mallet (preferably hardwood with a 3 inch diameter) to hammer the copper sheet around the form, the copper sheet itself and a pair of metal cutters. The recommended copper sheet is a soft temper, .021 inch thick copper sheet (also known as 24-gauge or 16-oz. copper sheet).

First, you will want to figure out what shape you want the post cap to be.
A basic triangular tip is a good choice. So, using the circular saw, cut the form (your piece of scrap post) to the desired shape.

Second, you might have to experiment, but cut the copper to the correct size for your particular post cap design. I might recommend using some scrap metal to experiment instead of valuable copper sheet. But it’s your choice.

Once you have your cutout, you can anneal the copper sheet to make it more pliable. However, the annealing is completely optional and not entirely necessary due to the copper sheet already being quite soft. Nevertheless, annealing is simply heating the copper sheet for an extended period of time, usually until it is glowing, and then allowing it to cool slowly. This heating can be performed with a common blowtorch.

Next, no matter if you choose to anneal or not, use the mallet to bend the copper around the form. A good technique for working the copper sheet is to pound the mallet in the way you want the metal to bend. This will work best if you can draw the mallet directly towards yourself while hammering.

Finally, to add a nice shine to the copper sheet cap, apply some sealant to keep the it bright and corrosion free.

And…Viola! You now have a beautiful copper sheet post cap! On a final note, be sure to wear eye protection and all the necessary safety equipment while operating any potentially dangerous tools. Hope you enjoy your new post caps!

If you would like more information on copper sheet with soft temper, select this link copper sheet for a fence post cap.

When a customer contacted Quick Ship Metals customer service staff looking for a solution, he thought it was a “strange request”, but it turns out he is only one of many with this same problem.

Custom cut copper sheet is available in any thickness.

Custom cut copper sheet is available in any thickness.

His email stated, “This may be a strange request but I’m having trouble finding what I need and you seem pretty versatile. Basically, all I need is a square-inch of 12-gauge copper sheet with both surfaces polished (smooth edges would be a nice touch).”

It turns out this individual repairs computers and the HP Laptop Models dv2xxx, dv6xxx, and dv9xxx all have a common design flaw involving the GPU (graphics processing unit), which causes it to overheat and become detached – making the laptop fail completely. These laptops come with a small thermal pad which wears out and doesn’t transfer heat very well. He stated, “It is possible to reflow the solder under the chip, which gets the laptop working again, but it is just a matter of time until it happens again. Replacing the thermal pad with a copper shim as described above greatly improves heat transfer and firmly secures the chip to the logic board which effectively makes the repair permanent.”

Fortunately, a solution was readily available because QSM has been getting numerous requests for this item every day. Copper transfers heat or cold readily, so it didn’t take long for technicians to start calling. Quick Ship Metals can custom fabricate any metal order, large or small, and usually it’s out the door in 24 hours. That’s where the name comes from: Quick Ship Metals!

Log on to the web site for a live chat session to solve your metal needs: quickshipMetals.com

When shopping for copper or stainless steel sheeting, and flexibility is an issue, here’s a tip to help you understand and compare the thickness and flexibility of these metals. The thickness of metal sheeting is listed in decimals. Metal sheeting with the thickness of .010, compared to our American system of fractions, would measure to less than 1/64 inch.

Now, let’s go one step further and give you a comparison of the flexibility of the metal that you can relate to an item in your everyday life. If you may have a Blockbuster membership card or a Bonus rewards card, copper sheeting with a .010 thickness will have the same flexibility as either of these cards.

Keep in mind that these two cards are thinner than a standard credit card which is less flexible. A standard credit card measures .028. This compares closely to .0216 copper foil, but the foil is slightly stiffer. Some other measurements that are convenient comparisons to everyday items are listed below.

Penny .050
Dime .062
Nickle .070
Quarter .067
Half dollar .085

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