Sheet Metal Layout and

Fabrication

Review of tools and terms

Basic layout principals
Safety procedures
Prepared by HT2 Jeffrey Bragg
 Safety Precautions

• Always refer to manufactures operating instructions.

• Take heed of all CAUTION and DANGER placards.
• Do operate any equipment not until properly trained.
• Wear gloves to protect hand from sharp edges.
• For more detailed instruction and precautions refer to
the following manuals:
– Hull Maintenance Technician, Blueprint Reading and
Sketching, Use and Care of Hand Tools, Mathematics
Volume 1, and relevant tech manuals.
 Common Terms

• Sketch: a rough outline of the structure to be

fabricated, gives dimensions and details of the job
to be done.
• Drawing: a sketch made with mechanical
drawing instruments drawn to scale.
• Blueprint: a duplicate of a drawing. Furnished
by the item manufacturer. Only accurate drawings
are blueprinted.
Combination Square

• Top: Making 90°

angles
• Bottom: Making 45°
angles
• Construct parallel
lines.
• Handle with care, or
inaccuracies will
result.
 Protractor Usage
• Used to construct any angle
• Place Protractor on baseline and mark vertex
• Mark any angle on the protractor
• Scribe from vertex to mark to form angle (60°
shown)
Trammel Points

• Used to make radii

larger than what
dividers on hand are
capable of.
• Set one point at the
center. Set the other at
the desired distance
tighten screws and
scribe arc.
Circumference Rule

• One edge graduated in

inches
• Opposite edge gives
approx..
circumference in
inches corresponding
to the diameter of the
circle
• I.E. 3” mark aligns
over 9 3/8”
Cylinder Variation Stretchout

• For circumference we
Need dimensions W,
L, and R
• Circum. = D+2W
• Ex. L=12 D=5, W=6
C=3.14 x 5 + 2 x 6
C=15.7+12
C=27.7
90° angle with dividers

-Draw line AB with straight

edge.
-Set dividers for >½ of AB
-Set pivot of divider on A and
swing arc at C and D
-Repeat at B
-Where arcs form ‘X’ is the
points ‘C’ and ‘D’
-Connect C and D for 90°
(perpendicular) line
 Bisecting Angle

• With ABC strike arc to

form arc ED.
• With D and E as pivots
strike an arc ‘X’ by setting
dividers to over ½ length of
arc ED
• Where arcs form ‘X’ is ‘F’
• Connect ‘B’ to ‘F’ to divide
ABC into two equal parts.
Divide a circle into six equal parts.

• With dividers set to

radius (AG)start at any
point on circle edge.
• From ‘A’ swing arc
across circumference to
form ‘B’
• From ‘B’ repeat process
till all 6 points are
formed.
• Connect ‘G’ to all points
Lay out of square or
rectangular elbow
• Lay out throat Radius
arc ST
• Add width of
cheek(ZS) to throat
radius to obtain heel
radius( arc ZY).
• Allowances for tabs
unnecessary if parts
are joined by welding
or brazing
Single and Double Hemmed Edges

• Hem edges strengthen the

piece, eliminate rough
edges. Improve appearance
• ‘W’ can be any width
• Heavier the metal, wider the
hem is made.
• Allowance for single hem is
equal to width of hem.
• Allowance for double hem
is twice the width of hem.
 Wired Edges

• Function to strengthen
and eliminate edges.
• 2.5 times wire diameter
will be the allowance
for the edge.
Allowance for Wired Notch

• Used with a wired edge

• Add one wire diameter
for cut-back allowance
(3 1/2 wire diameter)
• Example shows 45°
notch with 1 1/2 time
the width (W) of the
seam on each side of
the layout for seam
allowance
Seam Allowance

• Lap Types: Plain, Offset,

and Corner
• Joined by drilling and
riveting, solder or both.
• Allowance for lap base
on rivet diameter.
• Center of rivet must be
2½ times its diameter
from the edge as shown.
Groove / Pittsburgh Lock Seams

• Outside or inside design often

used on cylinders.
• Total allowance = 3W with
one half going to each edge.
• IE. Seam = ½”.
Allowance = 1 ½” with ¾”
used on each side of edge.
• Pittsburgh Lock Seam
allowance = 2W + 3/16”
• Flanged edge = W -1/16” for
tight fit into the lock.
Layout of a ¼” Pittsburgh Lock Seam
 Full V Notch

• Used to seam the ends of

boxes.
• Construct and cut out 90°
angle FDG as in ‘W’
• First Bend will be along
ADB see ‘Y’
• Final bend made along CD
as in ‘Z’
• A notch’s purpose is to
prevent binding while
bending sheet metal
Parallel Line Development

• This Principal assumes

that any line parallel to
another line is equal
distant from that line at
points.
• Cylinders and Boxes (not
cones) may be developed
using this method.
 Using half plans to transfer elevations to
stretchouts

Divide half plan in 6 parts and transfer the formed lines to

the stretchout forming twelve equal parts.
Parallel Line Development cont.

• By using side and elevation views a stretchout of the pattern is

developed.
• After transferring the stepped off lines the stretchout is ready to have
the seam allowances added.
 Radial Line
Development
• Same Principals as
Parallel line
development
• Used to form
stretchouts of cones
and funnels
• Add seam allowances
and stretchout is
complete
 Triangulation
Method
• Used to find the true
lengths of line from
orthographic views
• Method used to form:
square to round
off-center round to
round
and twisted square
transition pieces
Gauge and Decimal Measurements
of Low carbon Steel
• Tables for other
materials will vary.
• Gauge is often
stenciled on metal.
• Lower gauge =
thicker material
• Higher gauge =
thinner material.
• Snips for higher
gauges only
 Power Shears

• Only one blade moves

• Shearing starts at one
edge of the piece and
proceeds to the other.
• Each shear will have
minimum and
maximum gauge
cutting cutting values
and minimum amount
to be sheared.
Ring and Circle Shear

• Cuts Circle and Rings

of any radius equal to
the throat of the shear.
• May also be used to
cut irregular curves
• Follow Manufacture’s
instructions.
• AKA:
Throatless Shear
 Standard Cornice Brake

• Used for making uniform

bends in sheet metal work.
• Must be adjusted for gauge
of metal being bent.
• Bend radius determined by
clearance of upper jaw.
• Less ductile metals require
bending beyond the desired
angle to allow for spring-
back.
Always read the manual!!! • Useful for making hems and
seams
 Finger Brake

• AKA:
Box and Pan Break
• Removable Fingers of
various widths.
• Rearrange to form any
width of bend.
• Leave out fingers in
way of making a
proper bend.
 Hand forming
sheet metal
• Need two clamps,
angle iron, sturdy
bench, wooden mallet.
• Clamp angle iron over
sheet metal along bend
line.
• Use wooden mallet
minimize deformation
 Slip Roll Forming Machine

• Used for forming curved shapes.

• Front rolls grip the metal as it is fed in the machine.
• Rear roller is adjusted to control radius of bend for
forming cylinders, cones, and other curved shapes.
• Each machine has a range of metal it can bend safely.
 Slip rolling cones and wired edges

• Set back roll at angle or feed in at an angle for cones.

• Grooves at the end are used to roll wired edges, rods
or wires.
Forming grooved seams

• Bends made on
opposite sides and
ends of metal
• Hand groover 1/16”
wider than seam.
• Mandrel used as
backing during
setting-down
operation.
 Specialized metal forming tools:
Setting down and Crimping

Used for mashing seam together Corrugates the ends of cylinders thus
in hemmed fabrications reducing the diameter so it can fitted
into another cylinder of the same
diameter
 Wiring Roll

• Allowance is 1½ x diameter of wire for light

gauge. More for heavier gauges.
• Wire is first bent on the rotary turning rolls.
Metal Forming Stakes

• Used to back up sheet

metal for the forming
of many different
curves and angles and
seams
• Used to form small
diameter rods, cones,
setting seams, and
making irregular
bends.
Riveting Sheet Metal

• May be made of any

material.
• Use same material
when riveting.
• Weight of 1000 rivets
designates the size of
an individual rivet.
 Recommend Rivet Size for joining
sheet metal

• Minimum for rivets spacing is 2 ½ times rivet Dia.

• Lower gauges of sheet metal require heavier
weighted rivets.
 Correct and incorrect riveting.
• Rivets must be fully inserted
• Sheets to be joined must be in intimate contact.
• Pop rivets are normally used for blind
fastening where the back side cannot easily be
seen.
 Summary
• Refer to patterns often to ensure accurate layouts.
• Use print measurements listed, never directly
transfer a reading from the print.
• Use rosin paper for practice runs.
• Accuracy is a major concern. Measure twice cut
or bend once.
• Be aware of limitations of power driven
equipment.