I want to put a flat panel TV outside on our back porch, but since there is no overhang to keep it dry, I have an idea to make a metal enclosure for it. By hitting a switch, the TV will rise out of the box using an electric actuator. I am thinking that the top of the box would be attached to the mounting bracket, so that when the tv goes back in, the top would seal against/around the edges of the box (to keep out rain and thieves). I am actually using a Keyed switch to raise and lower the tv, so it should be secure from thieves. The dimensions for this would be approximately 32" wide by 36" deep by 7" deep. I have a few questions on this project that I am hoping to get some info on.
- What would be a better metal for this, steel or aluminum (protection from the elements)? I have never welded aluminum but do have the MIG conversion for my Weldpak 100HD and have always wanted to try and willing to learn. But I would want it painted and from experience , steel is much easier to paint for me.
- I am thinking of using 12 or 11 gauge for this. Would that be adequate? There would be a thicker lip at the top of the box to seal against.
- All the welding I have done so far has been with tube and angle iron. I have never really tried to weld any thin walled items into a three dimensional shape. What would be the best technique for welding something like this without too much distortion?
- One idea for the process would be welding four side pieces together and then the bottom on. But it would seem that getting into the box for welding from the inside would seem difficult. Is that the normal way to weld an enclosure, or would it be possible to weld from the outside? A second option would be to use a brake to bend all the sides together, and have one seam to weld. Unfortunately I do not have a brake, although Harbor Freight has one for 0.
Any starting points would be very helpful.
Thanks, Tom Kuhn