Material Thickness?

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First a little info, I am a photographer who loves to tinker, not a welder. I am loving my new hobby (welding with 115 v Mig welder) but got into it for building some props and sets, I have built them out of wood, foam etc but for a change going to do some metal props / sets. I am going to build a few blocks out of metal to go in a metal themed set and they need to be as light as possible but still hold a 250 lb football player if he sits on them. This would be no higher than 24" and sitting on the ground, so not like its going to be dangerous or huge. Just a block say 24"X30" that looks rugged to blend in with a rusty metal background. What size metal would you suggest. I am hoping I can go lighter than 1/8" as that would be quite heavy.
Reply:Filing cabinets are made from 14 to 18 gauge. I think it would really come down to how you form the boxes. You will certainly need some type of brake to bend an internal frame work. The bends add the strength. I'd look at some metal shelves, cabinets, and tool boxes to get a feel for how it's done. Maybe you can build the boxes out of plywood and skin them with thin sheet metal to get the look you desire.Of course stage guys are the master of faux finishes. They can paint foam to look like anything.Another option is something like this: http://www.fauxsteel.com/
Reply:you can use 1/16 walled 1 inch square tubing.  If you design it right to take the load, 115v mig welder certain is good enough to weld it.make a box, add some gussets.  it will be light, but sturdy.  I bought a bunch of 1x1x1/16" when i first started welding, and have been constantly surprised at how strong it is.
Reply:If you want a nice square box you should go to a sheet metal shop, they make metal boxes for air conditioning systems all the time, probably cheaper than you might expect. If you want to make it with a little more shape and character, I'd go with Oxy's suggestion of making a frame in the shape you want and then covering it with thin sheet metal. Starting from scratch with sheet metal can be a pain. With a frame I'd suggest 20 ga. without a frame i'd suggest 14 or 16ga.Ian TannerKawasaki KX450 and many other fine tools
Reply:Make a frame out of angle iron or square tube and cover it with sheetmetal.The frame is for the needed strength, the sheetmetal covers it all up.  All weldable with a 120V MIG machine.Want to get 'fancy'?  Make blocks in a couple different sizes and make them nestable for storage.  The best laid schemes ... Gang oft agley ...
Reply:If it is just going to be a Flat Sided Box, build it out of Wood and Faux finish it.If you need some type of Cage for some one to stand on then you can build with 16g TubingFor an idea of 16g StrengthSteel Deck specshttp://www.steeldeck.com/assets/dl/s...tions_1207.pdfhttp://www.steeldeck.com/index.htmEd Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:Thanks guys, will build a frame and cover it. I know I could build it out of wood, but half the project is to give me practice at welding.