I haven't worked with sheet-type metal since 'metal shop' in middle school. And I certainly don't have the right tools for it. But mind over matter, bite-the-bullet, I want a range hood! As usual, I go to my graph paper because mathematically, this one's a doozie (it looks worse than it was). I always try to get my projects to a place where they should work 'in theory' before I start experimenting with expensive supplies. I made a pattern, turned paper mock-up. It came out great, which means mad props to my high school geometry teacher.
But paper's pretty forgiving, it bends/moves without leaving a semi-permanent scar. So I graduated to cardboard. It's rigid and shows mistakes. Perfect for the dress rehearsal. I refined my pattern to three pieces and got the model made up. It too, looked awesome. But who wants a cardboard range hood?!
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It sat in my studio, looking awesome and soaking up my pride for about 2 weeks. Then, the only thing left to do, was (gasp) grow a pair. I had to make myself start bending and cutting this stuff:
I was very nervous. I went about it in a systematic way and I found a method to correct minor flaws. This copper is 36 gauge, which is metal-speak for 'thicker than aluminum foil' but 'thinner than posterboard'. It's about the same as cardstock. I guess.
I only messed up one piece beyond repair, so I had to make another exhaust duct. Otherwise, I'm pretty impressed with my learning curve.