Design: Determine first whether the tray is to be oblong or square. This material makes a tray 61⁄2 × 41⁄2 in. Draw this size oblong on a sheet of paper. The rim of the tray should be 3⁄8 in. wide. Draw an inner line all around, 3⁄8 in. from the outside. Below this draw your elevation, or edge view, showing the depth of the tray. In this design it is 1⁄4 in. deep.
First see that your 6-1⁄4 × 41⁄2-in. piece of copper is squared. Now draw your inner rectangle on the metal. To do this, set the dividers 3⁄8 in., and with one leg against the edge of the copper, draw all around the four sides, marking the lines on the metal. You now have a flat sheet marked ready for bending. Place the sheet of copper between the vise jaws, the inner line even and on a line with the vise.
The hard wood peg should be cut to a flat tapered end. This flat end of the peg is held at an angle of about 45° against the copper plate, just above the vise jaw and against the line of the rectangle. With the mallet drive gently. By doing this the body of the tray is pushed in, but the rim is kept straight in the vise. Repeat this all around. You'll have a tray like the sketch. If the body of the tray is not deep enough put it into the vise again and keep driving it until you get the depth you want. The inner corners will be found to be rounded, as they should be. Round off the outside corners to match. File the edges round and finish with an emery cloth, clean and polish as explained before.
V
PAPER CUTTER AND NUT SET
Let's make a paper cutter like this sketch. We can draw the design on paper first and then cut it out. Here is what we need to make it.
