THE QUICK AND DIRTY

Workshop tips from Mister Jalopy’s garage.

Holes, Rivets, and Bent Metal
Learn three essential shop fabrication techniques and
reward yourself by making a wi-fi signal deflector.
How to Drill Equidistant Holes in a Straight Line
Pegboard is underrated. Handy as can be. Think you are too good for
pegboard? Julia Child’s kitchen at the Smithsonian is practically a
pegboard temple.

¹ Clamp two sheets of sheet metal or plywood to extend over the edge of the bench.

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² Align, square, and clamp a strip of pegboard over the sheets.

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³ Use a pointy center punch to mark each hole. Every pegboard hole too many? Skip every other hole. Want staggered holes? Then stagger them!

 

⁴ Remove pegboard and drill holes.

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WARNING: Sheet metal wants to turn with the drill bit. Keep your fingers by always clamping the metal steadfast!

Drillin’ and Snippin’

Drill Big Holes

The Irwin High Speed Metal Unibit step drill bit is the best way to drill holes up to about 1½".

Drill Bigger Holes

What about big holes? Doorknob-size holes? Hole saws can drill holes up to 6". Buy a mandrel and the appropriate hole saws to Swiss-cheese your world.

Best Sheet Metal Shears for the Money

According to legendary custom car builder Gene Winfield, there is no better tin snip for the money than the Irwin Aviation Snip from Harbor Freight. Either the right or left snips will cut a straight line, but if you want to cut a left-leaning radius, you need the left snips. The same goes for a right-leaning radius.

What about all that leftover pegboard?

Hang it on the wall and get organized! A pegboard hanging hardware kit is under $2 and is adequate if you are planning to hang spatulas and wooden spoons. If you want hammers with outlines showing which goes where, screw a pegboard-size 1"x2" pine frame to the wall studs and attach the pegboard.

Illustrations by Damien Scogin