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What im planing on doing is getting some for sale sign from home depot, and cutting them to the size i need and adding some sheet metal to it. What size gage sheet metal should i get? would 26 or 28 gage work?

Thank you

26 gauge would be best for rigidity.. Honestly I would have used 1/8" birch plywood.. You can get it at any hobbystore that deals with planes..

I am not a fan of metal trays... I had a friend who used them, and when I once helped him put his army away, I ended up cutting my finger pretty severely...

I use sheet styrene. Its easy to cut, glue and you can lay either a metal liner into it or use sheet steel (its like sheet magnets material but not magnetized itself).

I use 2mm sheet Styrene with 2mm x 4mm styrene Rods.

Here is how I make them.

http://allyourswords.blogspot.com/2010/08/ive-got-movement.html

The metal sheet is meant to be an inlay on the tray, not the entire thing.

If your mate was using non-safe edged metals trays, he's an idiot. Does he juggle with razor blades, too?

I put sheet offcuts (HVAC guys are in my street) into existing mdf trays for magnetising. 26g galvanised sheet. They even cut it up for me.