How to build a wiring box.

So here's a little DIY for ya. I needed a better place to stuff a fuse box and hide my wiring on the Brattracker. I also thought it would be a nice place to keep other things outta Johnny laws eyes. Its pretty basic and well hidden. I built it using a Dremel with the heavy duty cut off wheel, 4 1/2" grinder with a cutoff wheel, Mig welder, a drill and a 6 pack of Stones. 

So step 1,  make yourself a pattern. I like using thin cardboard or poster board. Once you have that done, transfer your pattern to the metal. I used a 4 1/2" grinder with a cut off wheel to cut my basic pattern. These can be bought new at harbor freight for $20 or less. I shelled out $60 for my Milwaukee but it has a 5 year warranty.. Small pieces of sheet metal can be purchased at most hardware stores or your local metal supply company.

 Once all my patterns were cut, I started tack welding everything in place. I also used a dremel with a cut off wheel to cut the door out of the bottom of the box. The Dremel cutoff wheels are thin, and don't last long, but they are less than 1/16" in width which keeps me from having to cut out a new piece for the door.

 Almost ready for welding. For the vertical pieces I cut a strip 1 1/8" wide out of the same 10 gauge sheet material that I made everything else from. I achieved this using a 4 1/2" grinder with a cut off wheel and a 2x4 clamped to a table to use as a straight edge guide.

 Everything is tacked up and the door is now pop riveted in place. I used a simple cabinet hinge from  my local hardware store on the door. To keep the door closed I used some 1/4" all thread and a couple brass wing nuts also available at your local hardware store.

 Welded up the box using my Hobart 135 MIG welder with shielding gas.. I'm currently saving up for a TIG welding setup, but if you take your time your MIG will put out some pretty decent welds with a shielding gas of course..

The box fits very nicely under my seat. Everything will be going to powder coat soon, so you really wont even be able to see it. It holds a 6 position fuse box along with a large portion of my wiring. The funky wire you see is fish for the hole in my frame to hide my wiring. I welded a piece to the seat mounts on my frame to bolt the box up to. All in all my box was cheap, easy and functional and yours can be too;)