Sheet metal bead in a toolbox lid

[hedjhawg]

I am refurbishing/customizing a two-drawer carry-around toolbox (about 24" wide). The flip-top lid has had its share of stretches over the years. As a custom touch, and to "tighten up" the sheet metal lid, I want to roll a pair of parallel beads in the lid.

If this as was a flat sheet, rolling the beads would be easy. But this is an already-formed lid... that's a problem...

The second problem is that the piano hinge holding the lid to the box is welded on, and it won't come off. So, not only do I need to roll a bead on a formed lid, but I need to do so with the box "dangling" on the side.

In the picture, you can see the two ********* magic marker lines that show where I want to put the beads.

Does anyone have any ide of how to do this?

 

[s_ontario]

do you have a press

make up a die using some key stock

cost would be more than its worth

 

[gorilla]

Roll the beads on a sheet of thin metal spot weld it onto the toolbox and feather out he edges with the body filler of your choice?

 

[spartyon8]

Roll the beads on a sheet of thin metal spot weld it onto the toolbox and feather out he edges with the body filler of your choice?

That would work for aethstetic purposes but not for fixing the stretched metal like the OP wants to do. I agree, make a simple die and use in a press. That might be the easiest method.

 

[yhprum]

you can make a hammer from. cut two pieces of MDF same size. Bolt them together using the same hole spacing on the lid.
Using a router with a rounded bit, go all the way through one side, and however deep you want the beads to be.
Using the four holes, screw the two pices of wood onto the lid. Using a piece of round bar stock of the right size, and a hammer, form the metal into the groove on the MDF.
You might need to add some clamps at the edges to keep it all tight. And practice on some scrap material first.

 

[rsanter]

do you know somone with an industrial bead roller?

otherwise
you can take a piece of MDF and router a slot in it and then take a piece of nylon/delron
and round it over and then use it to make the bead

bob

 

[arkangel06]

I drilled out the spot weldes on the hinge of the box Im refurbushing.