The first thing is to gather the materials and draw up a plan. From left to right 5 oz. Latigo, Elkhide, one of my Batteries, the plans on graph paper, and a sheet of 18 gauge steel.

Step 1 is to cut the sheet into the pieces to be formed into the shell.

To keep the edges straight, I didn't use tin snips or aviation shears to cut the steel. I used this pneumatic nibbling tool. It's a really neat and fast way to cut sheet metal. But it throws out billions of these very sharp little crescents of steel. You don't want to track these all over the house and step on them barefoot. I know.

I clamped the metal to the edge of the tablesaw and used it as a guide for the nibbler.

I bent the shell to shape using two pieces of angle iron and the iron top of the tablesaw to fold the metal. It would be far better to have a sheet metal brake, but I don't, so I improvized.

Because of the slight curve of the bends, it was a good idea to inlet the end of the tab on the bottom here.

This is how the two pieces fit together.

This is the bottom pop-riveted together. I later used a centerpunch to knock out the center of the pop-rivits, and flattened them on the anvil. Very neat and smooth.

The tool on the right is a wonderful sheet metal punch from Harbour Freight. It puts the holes right where you want them, and cuts cleanly. Forget using a drill.

Here's the back rivited.

I smoothed over the seams on the bench grinder.

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