Here's the major tools I use to make this happen. Granted, I already own most of these tools so my upfront cost is not very high.
It is not really that difficult from a skills perspective - it's just a lot of labor. The thing that you'll need practice on the most is welding. Yes, it's easily possible to weld 20 gauge sheetmetal all day long without buckles, bows or bumps. You just need to use the proper technique to get it done the right way.
110 volt welder with a gas bottle: http://www.weldersupply.com/P/223/Mille ... WAutoSet11
(tack on another $300 for a cart, bottle, regulator, helmet, gloves)
Sheet metal shears: http://www.homedepot.com/p/Milwaukee-6- ... 5yc1vZc2a9
The rivet gun set (jazty convinced me!): http://www.amazon.com/Boulderfly-Deluxe ... 00AFJ33MI/
Air chisel: http://www.harborfreight.com/medium-bar ... 69866.html
Small Angle grinder: http://www.homedepot.com/p/DEWALT-4-1-2 ... 5yc1vZc2fw
Get flap discs, cutoff wheels, and a couple thick grinding wheels for the angle grinder.
Suction cups to lift the sheet metal panels into place and hold them: http://www.harborfreight.com/aluminum-s ... 92825.html
Dead blow to TAP (not hammer and then bend!) the panels into place: http://www.harborfreight.com/4-lb-neon- ... 41800.html
Cleco kit (check out the rivet gun kit, amazon suggests buying the same kit (about $60) that I got.
48" t-square for marking straight lines on steel sheet
Abrasive chop saw: http://www.amazon.com/DEWALT-D28710-14- ... B00551DJBQ
Straight pattern tin snip for minor adjustments: http://www.harborfreight.com/7-inch-str ... 66592.html
Various ratchets, wrenches, etc for taking crap apart
Cordless drill: http://www.homedepot.com/p/DEWALT-18-Vo ... 7fZ1z140i3
Various drillbits of the correct sizes.
Originally Posted by skrapgiarc
I would love to have the tools/ability to do this. Very nice!