A sheet metal ash pan for my reproduction cast iron fireplace. It’s only taken me 7 years to get around to dealing with this; better late than never! I generally don’t do much metal work, but I recently found a scrap sheet of thin steel being thrown out at work and thought it might do the job.
The first step in all this was making a template. Starting with a very rough paper template to work out sizes, I created a template in Sketchup. As this would use pretty thin material I ignored any bending allowances.
The template got glued straight onto my sheet metal with some spray adhesive, then I cut it out with a jigsaw. All pretty simple so far.
To fold this up nicely a break press would be the right tool, but with a lot of care I made do with some timber blocks, clamps, and some patient hammering.
Next came pop-rivets to lock the pieces all together. Most commercial pans like this are welded together, but I don’t have a welder, so rivets would have to do. In the end it was a little underwhelming and looking a little like a hack job, but with enough soot and charcoal this thing should get itself pretty dark and dusty so I figure it will do.