For a very first attempt, I'm extremely happy how this tray turned out: https://lyse.isobeef.org/tmp/blechschachtel/ The photos look rougher than in person. The 0.5mm aluminium sheet was 300x200mm to begin with. Now, the accidental outside dimensions are 210x110mm. It took me about an hour to make. Tomorrow, I gotta build a simple folder, so I don't have to hammer it anymore, but can simply bend it a little at a time.

@lyse very nice! What's the intended usage?

@lyse Not bad. 🤔 So this started out as a flat sheet and then you cut and folded it, like paper (more or less)?

@bender @movq Thank you! Not sure what I end up putting in there, but I'm sure I will find some tools to go in. :-)

Yes, this was a flat piece of sheet metal. It went together like a cardboard box, just much slower and with timbers clamped down to get a straight folding line. I don't have a sheet metal brake, so I just carefully hammered the piece bit by bit. Like in this video by the Sheet Metal Dude: https://www.youtube.com/watch?v=WYgEfWEMXk0

@lyse Very cool! 😎

@lyse Beautiful handwork, how did you seal the corners? I don't see and hole or anything.

BTW, That Sheet Metal Dude is something else himself, skilled enough to teach others, can work properly with self-imposed contraints, care about safety and is humble enough to be wiling to learn from others, a true craftman worthy of respect.

Haha, turns out, it's the perfect size to fit hankies: https://lyse.isobeef.org/tmp/blechschachtel/07.jpg

@lyse Just as planned! 😅