A MANUAL OF MACHINE SHOP PROJECTS

FOR HIGH SCHOOL STUDENTS

A P ro je c t
P r e s e n te d t o
th e F a c u l t y o f t h e S c h o o l o f E d u c a tio n
The U n i v e r s i t y o f S o u th e rn C a l i f o r n i a

In P a r t i a l F u lfillm e n t
o f th e R e q u ire m e n ts f o r th e D eg ree
M a s te r o f S c ie n c e i n E d u c a tio n

by
O tis C« K n ig h to n
Ju n e 1950
 UMI Number: EP45915

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 ii

BACKGROUND OF INDUSTRIAL ARTS EDUCATION

INTRODUCTION

S av ag es l e a r n e d , b y u n c o n s c io u s i m i t a t i o n o f t h e i r
f a t h e r s , t o o b t a i n s h i l l o f h a n d w h ic h g a v e them p o w er o v e r
t h e i r en v iro n m e n t* T h ese s k i l l s c o n s i s t e d o f m a n u fa c tu r e
an d u s e o f c r u d e t o o l s u s e d i n o b t a i n i n g n e c e s s i t i e s o f l i f e
f o r t h e f a m il y . T h ese c r u d e t o o l s w ere a l s o u s e d f o r
p r o t e c t i o n o f t h e f a m il y .
B a r b a r i c p e o p le l e a r n e d m anual a r t s th r o u g h c o n s c io u s
i m i t a t i o n o f t h e i r f a t h e r s an d c o n te m p o r a r ie s . Use o f f i r e
an d d i v i s i o n o f l a b o r i n t o c r a f t s becam e a c o n s c io u s
p r o c e s s , b u t t h e p r o c e s s w as n o t a r a t i o n a l i z e d o n e .
A n c ie n t Je w s e m p h a siz e d v a lu e o f h a n d iw o rk , te a c h i n g
r e l i g i o n i n t h e m o rn in g an d c r a f t s an d t r a d e s i n t h e a f t e r ­
noon. The r a b b i was i n c h a rg e o f t h e r e l i g i o u s t r a i n i n g and
t h e f a t h e r t a u g h t t h e s k i l l s t o h i s own s o n s . I t w as
b e l i e v e d t h a t i f a boy w as n o t ta u g h t a m an u al t r a d e he
w o u ld be a s o c i a l p a r a s i t e .
The B a b y lo n ia n Code o f Hammurabi, a b o u t 2250 B .C .,
s ta te s :
I f an a r t i s a n t a k e s a so n f o r a d o p tio n a n d t e a c h e s
him h i s h a n d i c r a f t , one may n o t b r i n g c la im a g a i n s t him .
I f h e d o e s n o t t e a c h him h i s h a n d i c r a f t , t h a t a d o p te d
s o n may r e t u r n t o h i s f a t h e r 1s h o u s e . 1

1 R o b e rt F r a n c i s H a r p e r , The Code o f H am m urabi, King

o f B ab y lo n (C h ic a g o : The U n i v e r s i t y o f C h icag o P r e s s , 1 9 0 4 ;,
p . 71.
 iil
T h is ty p e o f t r a i n i n g was c a r r i e d on u n t i l t h e

f a c t o r y sy stem a p p e a r e d . A b o y l e f t home an d becam e a p p re n ­

t i c e d to a c r a f ts m a n an d w o rk ed f o r t h e e d u c a tio n a n d b o a r d
he r e c e iv e d .,
In t h e M id d le Ages s k i l l s w ere t a u g h t in t h e m onas­
t e r i e s an d h a n d e d down. T h ese s k i l l s w e re u s e d f o r
r e l a x a t i o n a n d f o r b u i l d i n g up th e m o n a s t e r i e s . The monks
s p e n t much o f t h e i r tim e r e a d i n g , w r i t i n g , an d s tu d y i n g
r e l i g i o n ; t h e r e m a in d e r o f t h e i r tim e w as s p e n t i n t h e
c ra fts .

EARLY EDUCATIONAL LEADERS

The t h r e e e d u c a t i o n a l l e a d e r s who w ere m ost i n s t r u ­

m e n ta l i n s t a r t i n g m odern c o n c e p tio n s o f e d u c a tio n w ere
C om eniou8, P e s t a l o z z i , an d F r o e b e l . 2 The com bined i n f l u e n c e
o f t h e s e men b r o u g h t a b o u t fu n d a m e n ta l i d e a s upon w h ic h
m odern i n s t r u c t i o n i n m an u al a r t s h a s b e e n b u i l t . One o f
t h e s e i s t h a t s e n s e im p r e s s io n s a r e b a s e s o f th o u g h t an d
k n o w le d g e . T h is c o n c e p t b r o u g h t a b o u t t h e o b j e c t m eth o d o f
t e a c h i n g an d l a t e r th e l a b o r a t o r y m e th o d . The i d e a o f

2 C h a r le s A lp h eu s B e n n e tt , H i s t o r y o f M anual a n d
I n d u s t r i a l E d u c a tio n up to 1870 ( P e o r i a , I l l i n o i s : The
M anual A r ts P r e s s , 1 9 2 6 ) , p p . 3 6 - k l .
Sam uel J . Vaughn a n d A r th u r B. M ays, C o n te n t and
M ethod s o f t h e I n d u s t r i a l A r t s (New Y ork an d London: The
C e n tu ry Company, 1 9 2 4 ), p . 3 8 .
 iv

“l e a r n i n g b y doing*' r e c o g n i z e d t h e v a lu e o f w o rk in g th r o u g h
a p r o c e s s o f p r o d u c in g s k i l l f u l l y , s o m e th in g b a s e d u p o n
r a t i o n a l t h i n k i n g an d u s in g h a n d s and t o o l s . T h ese i d e a s
l e d t o t h e p l a c i n g o f c l a s s e s i n t h e s c h o o ls t h a t r e q u i r e d
m a n u al a r t s t r a i n i n g .
F in la n d , Sw eden, an d R u s s ia r e c o g n i z e d t h e e d u c a tio n ­
a l v a l u e s o f t h i s ty p e o f t r a i n i n g b e f o r e t h e U n ite d S t a t e s .
F i n l a n d w as t h e f i r s t t o p r o p o s e c o u r s e s i n m an u al t r a i n i n g ,
a n d i n 1866 made su c h c o u r s e s co m p u lso ry f o r b o y s i n r u r a l
c o m m u n itie s .3

The S w e d ish g o v ern m en t r e c o g n iz e d i n S lo y d a m eans o f

f u r n i s h i n g l e i s u r e tim e o c c u p a tio n s i n r u r a l c o m m u n itie s.
By r e v i v i n g h a n d i c r a f t s among th e p e o p le t h e movement from
c o u n tr y t o c i t y w as som ewhat c h e c k e d . S lo y d was l a t e r
t a u g h t i n o r g a n iz e d c l a s s e s i n t h e s c h o o l . T hese c l a s s e s
w ere co m p u lso ry a t f i r s t ; l a t e r th e y w e re made o p t i o n a l and
s u b s i d i z e d by t h e g o v e rn m e n t.
I n s p i r a t i o n f o r m an u al t r a i n i n g i n th e U n ite d S t a t e s
came from R u s s i a , a s a r e s u l t o f th e C e n te n n ia l E x p o s itio n
i n P h i l a d e l p h i a i n 1 8 7 6 .^ The R u s s ia n s l o g a n , “ I n s t r u c t i o n
b e f o r e C o n s tr u c tio n ,'* w as a r e s u l t o f V i c t o r D e ll a Vos*

i 3 C h a r le s A lp h eu s B e n n e tt , H i s t o r y o f M anual a n d
1 I n d u s t r i a l E d u c a tio n , 1870 t o 1917 ( P e o r i a , I l l i n o i s : The
M anual A r ts P r e s s , 1937)# p* 35*
** V aughan, o jd . c i t . , p . 26.
t e a c h i n g s — i n s t r u c t i o n i n s p e c i f i e d t o o l s and p r o c e s s e s
b e f o r e a p e r s o n w as a llo w e d t o c o n s t r u c t a n o b j e c t t h a t
r e q u ir e d u se o f th e to o ls and p ro c e s s e s . D r. C a lv in
Woodward an d J o h n D. R unkle w ere f a v o r a b l y im p re s s e d b y th e
R u s s ia n e x h i b i t i o n an d s e t a b o u t to d e v e lo p sh o p c o u r s e s i n
A m erican s c h o o ls * I t so h a p p e n e d t h a t A m erican i d e a s on
e d u c a ti o n w ere u n d e rg o in g a c h a n g e a n d t h e s c h o o ls w ere
r e a d y f o r t h e new m anual t r a i n i n g m ovem ent.

STAGES OF MANUAL TRAINING

The f i r s t s ta g e o f m a n u al t r a i n i n g i n th e U n ite d
S t a t e s may b e d e s i g n a t e d a s t h e a b s t r a c t e x e r c i s e o r J o i n t
s t a g e a s Im p o rte d from R u s s i a . T h is m eth o d was f i r s t u s e d
i n t h e S t . L o u is M anual T r a i n i n g S c h o o l a n d l a t e r t r a n s ­
f e r r e d t o o t h e r s c h o o ls . A d v o c a te s o f t h i s ty p e o f t r a i n i n g
e m p h a siz e d t h a t m an u al t r a i n i n g was f o r g e n e r a l t r a i n i n g ,
f o r c u l t u r e an d d i s c i p l i n e . They m a in ta in e d t h a t t h e t h i n g
l e a r n e d was r e l a t i v e l y u n im p o rta n t* b u t t h e p r o c e s s o f
l e a r n i n g w as w h at c o u n te d .5

The s e c o n d s t a g e o f m an u al t r a i n i n g i n A m erica was

t h e S w ed ish S lo y d w h ich m a t e r i a l l y m o d if ie d t h e R u s s ia n
ty p e o f w ork d u r in g t h e p e r i o d from 1886 to 1 9 0 0 .6 S lo y d

5 Ib id . , p . 27.
B e n n e tt , 1870 t o 1917* o p . c i t . , p* 38*
6 V aughan, o p . c i t . , p p . 2 6 -3 1 .
B e n n e tt , o p . c i t . , p . 3 6 .
 vi

w as revam ped t o p ro m o te t h e aim s o f s e l f - r e l i a n c e ; l o v e and

r e s p e c t f o r la b o r ; d e x t e r i t y In u se o f t o o l s ; and t r a i n i n g
i n h a b i t s o f o r d e r * e x a c tn e s s * n e a tn e s s * I n d u s tr y * a n d
p a t i e n c e t o p ro m o te p h y s i c a l d ev elo p m en t* H ow ever, a
s t r o n g e r h o ld o n p u p i l a n d p u b l i c w as b r o u g h t a b o u t b y th e
I d e a o f p r a c t i c a l u s e o f p r o j e c t s made* a s co m pared w i t h th e
R u s s ia n e x e r c i s e sy stem o f m ak in g p r o j e c t s t h a t h a d no
p ra c tic a l use.
R u s k in a n d M o rris p ro m o te d t h e i d e a o f m a in ta in in g
some sem b lan ce o f a r t an d b e a u ty i n m a n u fa c tu r e d g o o d s ,
t h e r e b y i n t r o d u c i n g th e a r t s a n d c r a f t s movement w h ic h con­
s t i t u t e s th e t h i r d s ta g e . I d e a ls o f th e a r t s and c r a f t s
s t a g e w ere seld o m a t t a i n e d * b u t m anual t r a i n i n g t e a c h e r s d i d
becom e c o n s c io u s o f th e f a c t t h a t su c h t h i n g s a s h o n e s t
c o n s t r u c t i o n , a r t i s t i c I d e a l s , b e a u ty i n s i m p l i c i t y , an d
o r i g i n a l i t y i n d e s ig n d i d e x i s t .
The f o u r t h s t a g e i s t h e a tte m p t t o i n d u s t r i a l i z e and
v o c a tio n a liz e th e sch o o l sh o p . I d e a s a lo n g t h e s e l i n e s
c o n s t i t u t e d t h e f o r e - r u n n e r s o f common th o u g h ts an d p r a c t i ­
c e s among i n d u s t r i a l a r t s t e a c h e r s o f to d a y . T h is s t a g e
b e g a n w ith t h e p r e s e n t - d a y c o n v i c t i o n t h a t sh o p c o u r s e s
s h o u ld b e a r a n i n t i m a t e an d d e f i n i t e r e l a t i o n t o th e
I n d u s t r i a l w o r ld . T h ere was a f e l t n e e d f o r I n c l u d i n g i n
sh o p c o u r s e s in f o r m a ti o n a n d e x p e r ie n c e s r e l a t i n g to
m a t e r i a l s * p r o c e s s e s * m e th o d s o f m a n u fa c tu re * a p p r e c i a t i o n
 vi I

o f s k i l l s , an d o t h e r i n t r i n s i c v a l u e s o f b a s i c i n d u s t r i e s .
T h is w as t h e s t a g e i n w h ic h t h e t e n s “m a n u al t r a i n i n g * w as
re p la c e d by " I n d u s tr ia l a r t s . " P r o p e r i d e a s an d c o n c e p ts
h a v e b e e n p u t f o r t h f o r " I n d u s t r i a l a r t s " an d s c h o o l sh o p
c o u r s e s h av e b e e n th o r o u g h ly i n d u s t r i a l i z e d .

MOVEMENTS IN UNITED STATES AFFECTING INDUSTRIAL ARTS

I n th e e a r l y p a r t o f t h e 1 9 th c e n t u r y , t h e r e w ere
o t h e r m ovem ents i n t h e U n ite d S t a t e s w h ic h h a d a d i r e c t
b e a r i n g on o u r p r e s e n t - d a y i n d u s t r i a l a r t s c o u r s e s .
F e l l e n b e r g 's Academy f u r n i s h e d i n s p i r a t i o n f o r t h e M anual
L a b o r Movement i n t h e U n ite d S t a t e s . The movement b e g a n
a b o u t 1825 an d r e a c h e d i t s p e a k a b o u t 1 8 3 ^ . I t d i d , h o w ev e r,
h a v e a p e rm a n e n t e f f e c t o n some s c h o o l s . ?
D r. B u b eG k 's M e ch an ics I n s t i t u t e s i n E n g lan d c a u s e d a
c o r r e s p o n d in g movement i n t h e U n ite d S t a t e s w here s e v e r a l
s o h o o ls w ere s e t u p i n an a t t e m p t t o b r o a d e n s e c o n d a ry
e d u c a tio n . C l a s s i c a l s t u d i e s d o m in a te d t h e i n s t i t u t e s , b u t
many c o u r s e s i n d ra w in g w ere g iv e n , t h e r e b y I n c r e a s i n g
m an u al t r a i n i n g . T h is movement was a r e s u l t , o f t h e common
p e o p l e 's t h i r s t f o r k n o w led g e .
The Lyceum movement s p r a n g u p i n A m erica an d f l o u r ­
i s h e d i n th e s m a ll to w n s, s e r v i n g th e same p u r p o s e s t h a t th e

? B e n n e t t , up t o 1 8 7 0 , o p . c i t . , p p . 128-1WJ-.
 v ili

M e c h a n ic s I n s t i t u t e s f u l f i l l e d I n t h e l a r g e c i t i e s . The
Lyceum movement f l o u r i s h e d I n E n g la n d a f t e r th e M e ch an ics
I n s t i t u t e movement d i e d down. A lth o u g h t h e s e m ovem ents d i d
n o t s t r e s s m an u al t r a i n i n g o r m anual a r t s , th e y d i d p la c e
e m p h a sis on " u s e f u l k n o w led g e" an d h e l p e d t o sh a p e t h e edu­
c a t i o n a l i n s t i t u t i o n s f o r t h e p r a c t i c a l i n s t r u c t i o n w h ich
f o llo w e d th em .

EXPLANATION OP TERMS USED

P e rh a p s a m is u n d e r s ta n d in g o f te r m s h a s c a u s e d a
g r e a t d e a l o f c o n f u s io n i n t h i s f i e l d o f t r a i n i n g s i n c e
s e v e r a l te rm s h a v e b e e n u s e d a t v a r i o u s tim e s t o d e s c r i b e
th e tr a in i n g . The u s u a l te rm s u s e d h a v e b e e n m an u al t r a i n ­
in g , p r a c t ic a l a r t s , and I n d u s tr i a l a r t s .
M anual t r a i n i n g was t h e a l l - i n c l u s i v e te rm u s e d t o
d e s i g n a t e t h e ty p e o f h a n d t r a i n i n g im p o r te d from R u s s ia .
B e in g a p h y s i c a l a c t i v i t y w h ere no m a c h in e ry was u s e d and
d i f f e r e n t from o t h e r ty p e s o f e d u c a ti o n , t h e name was
a d o p te d from i t s form r a t h e r th a n c o n t e n t . The t i t l e was
a n d s t i l l i s s u i t a b l e a n d r a t h e r d e s c r i p t i v e o f t h i s ty p e o f
a c tiv ity .®
P e o p le becam e d i s s a t i s f i e d w i t h t h e te rm m a n u al t r a i n ­
in g b e c a u s e th e y th o u g h t i t n a rro w an d n o t a c c u r a t e l y

Q
V aughn, o p . c i t . , p p . 5 6 -6 0 .
 ix

d e s c r i p t i v e o f t h e w o rk . The te rm m an u al a r t s was s u b s t i ­
t u t e d i n a n a t te m p t t o a f f i x t h e name t o t h e c o n te n t r a t h e r
th a n t h e form o f t h e w o rk . The te rm I n d i c a t e s t h a t t h e
p e o p le who c o in e d t h e t e r n w ere t h i n k i n g o f p r a c t i c a l s k i l l s
a n d a r t s i n w h ic h p e o p le u s e t h e s k i l l o f t h e i r h a n d s t o
a c c o m p lis h t h e i r w o rk .
P r a c t i c a l a r t s d e s i g n a t e s t h e n o n - v o c a t io n a l l i n e s o f
w o rk , f o r b o th b o y s an d g i r l s , n e e d e d t o g iv e e x p e r ie n c e
w i t h p r a c t i c a l w ork r e q u i r e d b y i d e a l s o f g e n e r a l e d u c a t i o n .
T h is te rm I n c lu d e s l i n e s s u c h a s h o u s e h o ld a r t s , a g r i c u l t u ­
r a l a r t s , i n d u s t r i a l a r t s , c o m m ercia l a r t s , e t c .
I n d u s t r i a l a r t s i s a te rm w h ich d e s i g n a t e s t h e
e n r i c h e d an d b ro a d e n e d p ro g ra m t h a t h a s come a b o u t a s a
r e s u l t o f m an u al t r a i n i n g a n d m anual a r t s . I t h as a b ro a d
c o n c e p t o f t h e w o rk an d c o v e r s a w id e v a r i e t y o f a r t i c l e s
t h a t g iv e a p p r e c i a t i o n a n d I n s i g h t t o a l l t h e " a r t s " t h a t
i n d u s t r y em ploys t o do t h e w ork a n d p r o d u c e t h e g o o d s o f
e v e ry d a y l i f e . I n d u s t r i a l a r t s i n c l u d e s a l l o f t h e h and
w ork a n d m an u al t r a i n i n g o f t h e lo w e r g r a d e s a n d t h e w id e
v a r i e t y o f sh o p a c t i v i t i e s i n t h e h ig h s c h o o l t h a t c o n s t i ­
t u t e s a w e ll- r o u n d e d c o u r s e f o r g e n e r a l e d u c a ti o n , a n d a r e
n o t d e s ig n e d t o p r e p a r e a s t u d e n t f o r u s e f u l em ploym ent i n
o n e o f t h e many s k i l l e d t r a d e s .
 x

PRESENT STATUS OF INDUSTRIAL ARTS

Today, I n d u s t r i a l a r t s i s c o n s id e r e d n e c e s s a r y i n a l l
h ig h s c h o o l c u r r i c u l a , an d i s a r e q u i r e d c o u r s e i n m o st
J u n i o r h ig h s c h o o l s . I t h a s n o t , i n t h i s p r o c e s s o f e v o lu ­
t i o n , r e c e iv e d any f e d e r a l a i d o r o th e r su b s id y , b u t h as
grow n o n i t s own m e r i t t o p r e s e n t p r o p o r ti o n s * P o p u la rity
f o r t h i s ty p e o f e d u c a ti o n d e p e n d s upon t h e a t t i t u d e s o f th e
s t u d e n t s , p a r e n t s , a d m i n i s t r a t o r s , an d g e n e r a l p u b l i c .
I n d u s t r i a l a r t s t e a c h e r s c a n w e l l b e p ro u d o f t h e i r
f i e l d o f e d u c a tio n . I t h a s grow n on i t s own m e r i t s a n d n o t
on some p r o m o tio n a l schem e. T oday, t h i s g ro u p o f t e a c h e r s
i s v e r y l a r g e a n d i s g ro w in g b y l e a p s a n d b o u n d s t o m e e t th e
dem and f o r m ore I n d u s t r i a l a r t s c o u rs e s *
E s tim a te s o f t h e num ber o f i n d u s t r i a l a r t s t e a c h e r s
v a r y from 2 0 ,0 0 0 t o 3 5 * 0 0 0 . A r e c e n t V o c a tio n a l A s s o c i­
a t i o n p u b l i c a t i o n g i v e s t h e num ber a s 3 0 ,0 0 0 . T h ese
t e a c h e r s p r o b a b ly m eet m ore th a n t h r e e m i l l i o n p u p i l s
d a ily * The s a t u r a t i o n p o i n t h a s n o t b e e n r e a c h e d . Many
m ore p r i n c i p a l s a n d s u p e r i n t e n d e n t s w o u ld l i k e t o add
i n d u s t r i a l a r t s to th e o f f e r in g s o f t h e i r s c h o o ls .
I n d u s t r i a l a r t s p ro g ra m s a r e b e in g i n s t a l l e d i n many
e le m e n ta r y s c h o o l s . 9
P r o s p e c t i v e i n d u s t r i a l a r t s t e a c h e r s m u st m e et h ig h
s t a n d a r d s f o r c e r t i f i c a t i o n an d c r e d e n t i a l i n g . In th is
f i e l d a r e m ore th a n se v e n h u n d re d c o l l e g e t e a c h e r s a n d f o r t y

® D eW itt H u n t, BThe P r o f e s s i o n a l i z a t i o n o f I n d u s t r i a l
A r t s T e a c h in g ,1* A m erican V o c a tio n a l J o u r n a l , Volume 23* p ag e
9 , O c to b e r, 1 9 ^ 8 .
o r m ore c o l l e g e s an d u n i v e r s i t i e s t u r n i n g o u t I n d u s t r i a l
a r t s t e a c h e r s a n d men g o in g i n t o o t h e r r e l a t e d o c c u p a t i o n s .
Many o f t h e s e s c h o o ls o f f e r t h e M a s t e r 's d e g r e e a n d some a r e
c o n s i d e r i n g o f f e r i n g a D o c t o r 's d e g r e e i n I n d u s t r i a l a r t s .
G re a t s t r i d e s h av e b e e n made an d much a c c o m p lis h e d i n
t h e l a s t t h r e e d e c a d e s to w a r d a t t a i n i n g a r e s p e c t a b l e p la c e
i n t h e c u r r ic u lu m f o r i n d u s t r i a l a r t s s u b j e c t s . The u n f o r ­
t u n a t e s i t u a t i o n a t p r e s e n t , i s t h a t a f t e r m aking t h e s e
c o n s t a n t g a i n s i n s t a t u s a n d p u r p o s e f o r so lo n g t h a t i t i s
f a l l i n g i n t h e p r im a r y p l a c e w ith t h e s t u d e n t . A lto g e th e r
to o many s t u d e n t s a r e t u r n i n g away from o r j u s t e n d u r in g t h e
I n d u s t r i a l A r t s M achine Shop c o u r s e b e c a u s e i t d o e s n o t
c h a l l e n g e them a n d b e c a u s e t h e t h i n g s t h e y have t o make a r e
s u it e d to th e te a c h e r and to th e o ry , b u t n o t to b o y s.

MATERIALS AVAILABLE AT PRESENT

One c a n assum e t h a t t e a c h e r s , s e e k in g a d v a n c e d
d e g r e e s i n t h e f i e l d o f I n d u s t r i a l A r t s , w i l l a tte m p t t o
p ro d u c e m a t e r i a l s t h a t w i l l b e n e f i t b o t h s t u d e n t s a n d them ­
s e lv e s . Much w ork h a s b e e n d o n e i n p r o d u c in g m a t e r i a l s f o r
I n s t r u c t i o n i n some o f t h e I n d u s t r i a l A r t s c o u r s e s . T h ere
a r e s e v e r a l g o o d t e x t b o o k s , w ork b o o k s , a n d a few p r o j e c t
b o o k s on th e m a rk e t f o r t e a c h i n g m ach in e sh o p . T h e re i s a
r e a l n e e d f o r a l a b o r a t o r y m a n u al o r p r o j e c t book c o n t a i n i n g
a v a r i e t y o f i n t e r e s t i n g and u s e fu l p r o j e c t s . H ow ever, upon
 x ii
i n v e s t i g a t i o n o f t h e h ig h s c h o o ls i n t h i s a r e a i t w as fo u n d
t h a t many o f them do n o t u s e a te x tb o o k , n o r a g u id e o f an y
d e s c rip tio n . T h e se s c h o o ls u s in g t e x t b o o k s , w o rk b o o k s, and
p r o j e c t b o o k s h a v e fo u n d them in a d e q u a te t o m eet t h e n e e d s
o f th e s tu d e n ts .
Books b e i n g u s e d w ere re v ie w e d a n d i t w as fo u n d t h a t
th e y u s u a l l y f a l l i n t o f o u r g ro u p s o r c l a s s i f i c a t i o n s . The
f i r s t a n d m o st f r e q u e n t l y u s e d g ro u p o f b o o k s a r e a c a d e m ic
i n n a t u r e , c o n c e n t r a t i n g on th e o r y a n d p r o c e s s e s . They w ere
f u r t h e r c l a s s i f i e d a s b e in g o u t o f d a t e , to o d i f f i c u l t f o r
t h e b e g in n in g m a c h in e sh o p s t u d e n t s t o r e a d , and th e y a r e
w r itte n s p e c i f i c a l l y f o r v o c a tio n a l s tu d e n ts . In s h o r t,
t h e y a r e to o a d v a n c e d , to o co m p lex , o r c o n t a i n m a t e r i a l t h a t
i s o u td a te d o r I r r e l e v a n t .
The s e c o n d g ro u p w ere c l a s s i f i e d a s w ork b o o k s .
T h ese a r e made u p o f q u e s t i o n s t h a t a r e t o b e a n s w e re d by
t h e s t u d e n t a f t e r r e a d in g t h e b o o k s m e n tio n e d i n t h e f i r s t
g ro u p . T h is i s a v e r y p o o r m ethod o f i n s t r u c t i o n a n d h a s
b e e n fo u n d u n s a t i s f a c t o r y .
N ext c o n s id e r e d w ere m a n u als p u b l i s h e d by m a n u f a c tu r ­
e r s o f m a c h in e ry . T h ese a r e e x c e l l e n t i n t h a t th e y a r e
a d e q u a t e l y i l l u s t r a t e d , and a r e w r i t t e n d i r e c t l y t o t h e
b e g in n e r. H ow ever, th e y a r e d e s ig n e d t o b e u s e d i n o p e r a t ­
in g a s p e c i f i c b r a n d o f m a ch in e an d do n o t c o v e r th e v a r i e t y
o f m a c h in e s u s e d . The m a n ip u la tiv e p r o c e s s e s a r e w e l l
 x iii

e x p l a i n e d , b u t t h e r e i s n o th in g d e f i n i t e f o r th e s t u d e n t t o
do i n o r d e r t o p r a c t i c e t h e s e p r o c e s s e s . F o r e x a m p le , a
m a n u al w i l l go I n t o a d e t a i l e d e x p l a n a t i o n o f t h e p r o c e d u r e
f o r c u t t i n g s c re w th r e a d s b u t f a l l s t o g iv e t h e s t u d e n t a
jo b t h a t w i l l m o ti v a te him t o c u t sc re w t h r e a d s .
Books t h a t w ere d e s ig n e d t o m eet t h e n e e d m e n tio n e d
ab o v e f a l l i n t o a g ro u p c a l l e d p r o j e c t s b o o k s o r m ach in e
sh o p c o u r s e s f o r a p p r e n t i c e s . T h e i r f a i l u r e i s t h a t th e y
w e re d e f i n i t e l y d e s ig n e d f o r v o c a t i o n a l c l a s s e s o r a p p r e n ­
tic e tra in in g . They p r e s e n t e i t h e r a n a rro w s e l e c t i o n o f
p r o j e c t s d i r e c t e d a t i n d u s t r i a l o b j e c t i v e s , o r a r e o f su c h
l i m i t e d v a r i e t y t h a t th e y w i l l n o t s u f f i c e . M o ti v a ti o n ,
w h ic h m u st n e c e s s a r i l y come i n a g r e a t p a r t from t h e p r o j e c t
i t s e l f , i s m is s in g .

PURPOSE OF THIS SYLLABUS

The s c h o o ls n o t u s i n g p u b l i c a t i o n s o f th e ty p e men­
t i o n e d above w e re u s in g v a r i o u s t e a c h e r made m a n u a ls . The
m ore e x p e r ie n c e d t e a c h e r s . h a v e g r a d u a l l y b u i l t u p a s u p p ly
o f " p e t * p r o j e c t s to be tu r n e d o u t by th e s tu d e n ts . Some o f
t h e s e p r o j e c t s a r e good a n d t h e s t u d e n t s a r e e a s i l y m o tiv a ­
t e d t o w ork a n d p ro d u c e th em . H ow ever, t h i s i s n o t a lw a y s
th e c a s e . Some t e a c h e r s h a v e a s m a ll num ber o f u n i n t e r e s t i n g
p r o j e c t s t h a t th e y fo rc e upon th e s tu d e n ts y e a r a f t e r y e a r.
I t i s h o p e d t h a t a s y l l a b u s c a n b e p r o v id e d t h a t
c o n t a i n s a v a r i e t y o f i n t e r e s t i n g p r o j e c t s t o b e made i n t h e
m a c h in e sh o p . T h is s y l l a b u s s h o u ld c o n t a i n p r o j e c t s r a n g in g
from th e s im p le , e a s y -to -m a k e p r o j e c t s , t o t h e c o m p lic a te d ,
d iffic u lt-to -m a k e p ro je c t. U s in g t h i s s y l l a b u s , t h e b e g in ­
n in g t e a c h e r c a n s t e p i n t o t h e c la s s r o o m an d t e a c h h ig h
s c h o o l s t u d e n t s o f v a r io u s l e v e l s . The s t u d e n t s o f a l l
l e v e l s o f a b i l i t y w i l l h a v e w ork t h a t w i l l r e q u i r e them t o
u t i l i z e t h e i r maximum c a p a b i l i t i e s , an d t h e c o u r s e I t s e l f
w i l l n o t s u f f e r from t h e p o o r q u a l i t y a n d s e l e c t i o n o f
p ro je c ts .

METHODS USED TO OBTAIN MATERIAL

In o rd e r to c r e a te su ch a s y lla b u s , a d i f f i c u l t y a n a l
y s i s w as m ade. One h u n d re d h ig h s c h o o l s t u d e n t s who h ad
o o m p le te d a minimum o f one s e m e s te r o f m ach in e sh o p w ere
i n v i t e d t o s t a t e s e v e r a l o f t h e i r w a n ts on s m a ll s l i p s o f
p a p e r. S e v e ra l in d u s t r ia l a r t s te a c h e rs c o n trib u te d s li p s
lis tin g s tu d e n t n e e d s. The w r i t e r u s e d r e c e n t p r o j e c t s and
s y l l a b i from th e f u n c t i o n a l e d u c a ti o n l i b r a r y an d h i s
b a c k g ro u n d o f f i v e y e a r s t e a c h i n g e x p e r i e n c e i n t h e f i e l d t o
draw upon f o r a t h i r d l i s t o f n e e d s t o b e m e t.
U sin g t h e d i f f i c u l t y a n a l y s i s a s a g u id e , a g ro u p o f
p r o j e c t s w ere s e l e c t e d an d d e s ig n e d t h a t w ould m o st n e a r l y
m eet t h e n e e d s o f m o st s t u d e n t s . Ten y e a r s o f e x p e r i e n c e
■>

w ere u t i l i z e d i n t h e s e l e c t i o n an d d e s ig n o f t h e s e p r o j e c t s .
some o f w h ic h a r e b e in g u s e d t o a h ig h d e g r e e o f s a t l s f a e
t i o n a t th e p r e s e n t tim e . The r e m a in d e r o f t h e p r o j e c t s
w i l l u n d erg o e x p e r i m e n ta tio n i n t h e n e a r f u t u r e .
 PREFACE TO THE TEACHER

Do y o u h a v e e n o u g h i n t e r e s t i n g p r o j e c t s f o r y o u r

s t u d e n t s t o keep them o c c u p ie d i n t h e i r m achine shop c l a s s ?

I f n o t, perhaps t h is s y l l a b u s w i l l be of a s s i s t a n c e to you.

The m a t e r i a l g a t h e r e d f o r t h i s w o r k c o v e r s a w i d e a r e a ; from

p r o je c ts f o r begin n in g s tu d e n ts through the p r o je c ts for

advanced s tu d e n ts . The m a t e r i a l i s d i r e c t e d t o t h e student

i n a n a t t e m p t t o g u id e him i n t h e d i f f i c u l t i e s h e e n c o u n t e r s

The s y l l a b u s was n o t d e s i g n e d t o r e p l a c e the e x c e l­

l e n t m a t e r i a l now e x i s t i n g w h i c h was d e s i g n e d t o g i v e t h e

s t u d e n t know ledge o f p r o c e d u r e s an d p r o c e s s e s . N e i t h e r was

th is sy lla b u s in ten d ed to re p la c e the t e a c h e r s ’ le c tu r e and

dem o n stratio n , b u t s h o u l d go h a n d i n h a n d w i t h t h e s e d e v i c e s

It s h o u l d b e u s e d a s a n a i d t o g u i d e t h e s t u d e n t t o do c o r ­

rec tly , o p e r a t i o n s and p r o c e s s e s t h a t he h a s b e e n a t t e m p t i n g

t o d o , w i t h m u ch d i f f i c u l t y , in the p a s t w ithout such a

guide. He w i l l s t i l l b e d e p e n d e n t o n o t h e r i n s t r u c t i o n a l

m ateria l, teacher le c tu re s, au d io v is u a l m a te r ia ls , and a

c e r t a i n amount o f i n d i v i d u a l in stru ctio n .

S t u d e n t s t a k i n g m achine shop i n t h e p a s t e x p r e s s e d a

desire t o make c e r t a i n t o o l s f o r t h e i r own u s e . (These

d e s i r e s were e x p r e s s e d on s l i p s f i l l e d o u t b y one h u n d r e d

h i g h s c h o o l s t u d e n t s h a v i n g h a d one o r more s e m e s t e r s o f

m achine s h o p ) . T his s y l l a b u s g iv e s th e s t u d e n t a v a r i e t y
 x v ii

o f u s e f u l t o o l s t o b e m ade I n o r d e r t h a t h e may h a v e some

ch o ice in th e p r o j e c t s he s e l e c t s . The p r o j e c t s r a n g e fro m

the sim p le, easy-to -m ake, to o ls to t h e more c o m p l i c a t e d ,

d iffie u lt-to -m ak e, to o ls; th e re b y c h a lle n g in g the c a p a b il i ­

tie s of a ll.

The p r o j e c t s s e l e c t e d s e r v e two p u r p o s e s . They p r o ­

v i d e d i r e c t i o n s f o r m a k i n g a p r o d u c t t h a t t h e s t u d e n t may

w e l l b e p r o u d t o own. They a l s o p r o v i d e ex p lo rato ry expe­

rien ces in s k ills and p ro c e s s e s needed by s tu d e n ts i n

in d u stria l a rts courses.

The s y l l a b u s i s d iv id ed in to th re e p a r ts . The f i r s t

p art, p ro jec ts fo r f i r s t sem ester s tu d e n ts , provides

e x p e r i e n c e s i n b e n c h work w h ic h i n v o l v e s w o r k in g w i t h

v a rio u s hand t o o ls , a n d l i m i t e d e x p e r i e n c e s o n some o f t h e

m achines. The s e c o n d p a r t , p r o j e c t s f o r second sem ester

stu d en ts, is d e v o te d a l m o s t e n t i r e l y t o l a t h e work. The

th ird p a rt, p ro jec ts fo r advanced s tu d e n ts , r e q u i r e s work

i n a l l p h a s e s o f m achine shop work.

The p e r m i s s i o n t o u s e p r o j e c t n o . 21, the bench v is e ,

ta k e n from Ja n u a ry , 19^ 8» i s s u e o f School Shop, i s a p p r e c i ­

ated .
 x v iii

PREFACE TO THE STUDENT

How w o u l d y o u l i k e t o make t o o l s a n d o t h e r u s e f u l

a rticles i n y o u r m achine shop c l a s s ? I f you do, f o l l o w th e

id eas o ffere d in t h is s y l l a b u s to g u id e you i n t h e p ro b lem s

t h a t you w i l l e n c o u n te r . To b e s u c c e s s f u l i n m a k i n g a s s i g n e d

p ro jec ts, it w i l l b e n e c e s s a r y f o r y o u t o do r e l a t e d r e a d i n g

as assig n ed , and to pay c a r e f u l a t t e n t i o n t o l e c t u r e s and

th e audio v is u a l m a te r ia ls p re s e n te d by th e te a c h e r .

Form er s t u d e n t s t a k i n g t h i s course e x p re ssed a d e s ire

t o make t o o l s t h a t c o u l d b e u s e d i n t h i s and o t h e r c o u r s e s

a t school. Many o f y o u h a v e a c c e s s t o home w o r k s h o p s . In

such c a s e s , th ere s h o u l d b e a d d e d i n c e n t i v e f o r y o u t o make

s e v e r a l t o o l s t h a t may b e u t i l i z e d i n t h e home s h o p . For

t h o s e o f y o u who do n o t h a v e s u c h a n o p p o r t u n i t y , you sh o u ld

co n cen trate your e f f o r ts on m a k i n g t o o l s t h a t w i l l b e o f u s e

to th e e n t i r e fa m ily around th e house. There a r e several

in te re s tin g p ro jects f o r owners o f c a r s and m o to r s c o o t e r s .

The s y l l a b u s p r o v i d e s p r o j e c t s t h a t w i l l c h a l l e n g e

the c a p a b i l i t i e s of each of you, r e g a r d l e s s o f t h e l e v e l on

w hich you a re p a r t i c i p a t i n g . F irst s e m e s t e r s t u d e n t s may

s e l e c t one p r o j e c t f r o m n um bers one and two; but p ro jects

t h r e e and fo u r a r e b o th r e q u i r e d to com plete f o u r p r o j e c t s

from th e s ix assig n ed .
 x ix

The a d v a n c e d s t u d e n t s a r e e n c o u r a g e d t o s e l e c t and

c o m p l e t e a s many p r o j e c t s a s t h e y a r e c a p a b l e o f c o m p l e t i n g .

A ll p r o je c ts a re d esigned to provide e x p erien ces in d e v el­

oping s k i l l s i n t h e u s e o f common h a n d a n d m a c h i n e t o o l s .

You m u s t r e a l i z e , how ever, th a t m an ip u lativ e sk ills

a re o nly a p o r t i o n of th e b e n e f i t s you should d e riv e from a

c o u rs e i n m achine shop. You s h o u l d l e a r n t o w o r k c o o p e r a ­

tiv e l y w ith o th e rs , sh a re t o o l s and i d e a s , give a s s i s t a n c e

i f necessary. You s h o u l d l e a r n s h o p r o u t i n e and p ro c e d u re ,

and g a i n a n a p p r e c i a t i o n o f what a c t u a l l y t a k e s p l a c e i n

o r d e r t o p r o d u c e t h e n e c e s s i t i e s a n d l u x u r i e s we e n j o y

today. Ab o ve a l l , h e a l t h and s a f e t y s h o u ld n o t be o v e rlo o k e d

in your eager d e s ir e to le a r n the m a n ip u lativ e s k i l l s . You

sh o u ld be t h i n k i n g ab o u t y o u r f u t u r e a n d b e a b l e t o make a

l o g i c a l c h o i c e a s t o t h e t y p e work you w ould l i k e t o do.

F in d o u t i f you a re m e c h a n ic a lly in c l i n e d ,’ Would y o u b e

h a p p y i f y o u r l i f e ’ s w ork was t h a t o f a m a c h i n i s t o r i n some

re la te d trad e?
 xx

TABLE OP CONTENTS

CHAPTER PAGE

PART I . THE NOVICE

PROJECTS FOR FIRST SEMESTER STUDENTS

1. DRILL GAGE: How t o make a t o o l t o c h e c k t h e

c u t t i n g a n g l e o f d r i l l s .............................................................. 2

2* DRILL DRIFT: How t o f a b r i c a t e a t o o l t o r e m o v e

d r i l l s and chucks from th e s p i n d l e of th e d r i l l
p r e s s ....................................................................... 7

3* COLD CHISEL: How t o f o r g e a t o o l t o c u t a n d

s h e a r m e t a l ................................... 12

I).* BUSHING REMOVER: How t o make a t o o l t o r e m o v e

w orn b u s h in g s .................................................................. 18

5* CENTER PUNCH: How t o make a t o o l f o r l a y i n g o u t

h o le s to be d r i l l e d . . . . . . . . . . . . . . . 23

6. PRICK PUNCH: How t o make a t o o l f o r m a r k i n g

s c r i b e d o r l a y o u t l i n e s .............................................................. 28

7« DRIFT PUNCH: How t o make a t o o l f o r r e m o v i n g

b o l t s o r r i v e t s b y f o r c e ......................................................... 33

8. NAIL SET: How t o m ak e a t o o l t o s e t n a i l s b e l o w

th e s u r f a c e i n t o w hich th ey have been d r i v e n . . 38

9. PLUMB BOB: How t o m ake a t o o l t o c h e c k v e r t i c a l

s t r u c tu r e s to determ ine i f th e y a re p e rp e n d ic u la r Ip3

10. SCRIBER: How t o c o n s t r u c t a t o o l t o b e u s e d t o

mark o r l a y o u t w o r k ........................................................................ J^.8

PART I I . THE AMATEUR

PROJECTS FOR SECOND SEMESTER STUDENTS

11. SCREWDRIVER: How t o c o n s t r u c t a t o o l t o t u r n

screw s ................................................................................................. 53

12* DIESTOCK: How t o make a h o l d e r f o r d i e s u s e d

fo r c u ttin g e x te rn a l th read s ............................................... 59
 xxi

CHAPTER PAGE

13* ,fT tt TAP WRENCH: How t o c o n s t r u c t a h o l d i n g d e -

v ice fo r tap s used fo r c u ttin g in te r n a l th read s 65

llj.. COMBINATION CENTER PUNCH: How t o c o n s t r u c t a

t o o l f o r m a r k in g h o l e s t o be d r i l l e d a n d f o r
t o o l i n g m e t a l ........................................................................................ 71

15« PARALLEL CLAMP: How to make a d e v i c e for hold­

ing work in p o s i t i o n ............................ J8

PART I I I . THE PRO

PROJECTS FOR ADVANCED STUDENTS

16. SOCKET WRENCH FLEX HANDLE: How t o make a d e v i c e

f o r h o l d i n g a n d t u r n i n g s o c k e t s ......................................... 85

17* **V« BLOCK AND CLAMP: How t o c o n s t r u c t a t o o l

f o r h o l d i n g r o u n d s t o c k i n p o s i t i o n ............................... 91

18. GEAR PULLER: How t o f a b r i c a t e a d e v i c e f o r

rem oving g e a r s and p u l l e y s . . . . . . . . . . . 97

19# FLARING TOOL: How t o m a k e a t o o l f o r s h a p i n g

t h e e n d s o f t u b i n g ........................................................................ 103

20* PRESSURE PUMP: How t o m ak e a d e v i c e t o s u p p l y

a i r f o r keeping gas tanks under p re s s u re . . . . 112

21. BENCH V I S E : How t o c o n s t r u c t a t o o l f o r h o l d i n g

work w h i l e i t i s b e in g f i n i s h e d o r a s s e m b le d
a t t h e b e n c h .................................... 119

22. ADJUSTABLE TAP WRENCH: How t o c o n s t r u c t a n

a d j u s t a b l e w r e n c h f o r t u r n i n g t a p s ............................... 132

23. COMBINATION LAYOUT SET: How t o make a s e t o f

t o o l s c o n s i s t i n g o f hammer, c e n t e r p u n c h , and
s c r a t c h a w l ............................................................................................. lij.0

2 l\.* CONFEDERATE CANNON: How t o f a b r i c a t e a m o d e l

1 2 - l b . b ro n z e m uzzle l o a d i n g h o w i t z e r ..................... 1 I4.8

25* SMALL SCREWDRIVER: How t o m ak e a t o o l f o r

turning small s c r e w s ........................... l5i}-
 x x ii

CHAPTER PAGE

26. SINGLE POINT SCRIBER: How t o make a tool to be.

u s e d t o m a r k o r l a y o u t w o r k ...................................................... l£8

27* PENDER HAMMER: How t o make a t o o l f o r r e p a i r i n g

d a m a g e d f e n d e r s .................................................................. 163

28* FLEX HANDLE: How t o m a k e a s o c k e t w r e n c h f l e x

h a n d l e w i t h a 3 / 8 Md r i v e ................................................................ 167

B I B L IOGRAPHY ........................................................................................................... 171

 x x iii

L IS T OP BLUEPRINTS

BLUEPRINTS PAGE

1* D r i l l G a g e .............................................................................................. 6

2. D r i l l D r i f t .............................................................................................. 11

3. C o l d C h i s e l ........................................................................................... 17

!{.• B u s h i n g R e m o v e r ................................................................................. 22

5. C e n t e r P u n c h ............................................................ 27
6. P r i c k P u n c h .............................................................................................. 32

7. D r i f t P u n c h ............................................................................................... 37

8. N a i l S e t .................................. i|2

9* P l u m b B o b ................................................................................................. lj.7

10. S e r i b e r ..................................................................................... 51

11* S c r e w d r i v e r ........................................................................................... 58

12* D i e s t o c k ................................................................................................. 61j.

13• " T " Tap W r e n c h .................................................................................. 70

lip* C o m b i n a t i o n C e n t e r P u n c h ............................. 77

15* P a r a l l e l C l a m p .................................................................................. 83

16 . S o c k e t W r e n c h F l e x H a n d l e ........................................................ 90

17, B l o c k a n d Clamp 98

18 • Gear P u lle r .................................................................. 102

19 • F l a r i n g T o o l ...................................................................................... Ill

20. P r e s s u r e P u m p ....................................................................................... 118

21. B e n c h V i s e ............................................................................................ 126

21A . S t a t i o n a r y J a w ................................................................................. 127

 x x iv

BLUEPRINTS PAGE

21B. M o v a b l e J a w ............................................................................................ 128

21C. V i s e G u i d e ............................................................................................ 1 29

2 1 D . V i s e B a s e ...................................................................• ............................ 130

21E. V i s e H a n d l e ............................................................................................ 1 31

22 .' A d j u s t a b l e Tap W r e n c h .................................................................. 139

23. C o m b i n a t i o n L a y o u t S e t ......................................................... llj.7

24. C o n f e d e r a te Cannon ................................................................... 153

2 5*' S m a l l S c r e w d r i v e r ............................................................................ 157

26. S ingle P o in t S c rib e r .................................................................. l62

27. P e n d e r H a m m e r ....................................................................................... l6 6

28. P l e x H a n d l e ............................................................................................ 170

 1

PART I . THE NOVICE

PROJECTS FOR FIRST SEMESTER STUDENTS"

These projects were selected specifically for the

beginning machine shop student* for two reasons: the desire

of every boy to possess some tools of his very own; and the

desire he has to make something with his hands and machinery*

All of the tools can be used in other industrial arts

classes to assist you in doing a better job, or they may be

U3ed in the home work shop# Often parents and relatives

have a need for small tools like these in their home or at

work* They will appreciate them as gifts from you and often

will be happy to pay for them.

It makes little difference whether you make the tool

for yourself or for others as you will have gained knowledge

and skills from creating it. You will also know if you like

this type of work well enough to explore it further*

 2

CHAPTER 1 . DRILL GAGE

HOW TO MAKE A TOOL TO CHECK THE CUTTING ANGLE OP DRILLS

Im p ro p erly sh arp en ed d r i l l s w i l l produce h o le s th at

are in c o rre c t in siz e and f i n i s h . You w i l l b e r e q u i r e d t o

sharpen d r i l l s from tim e t o tim e, and, i n o r d e r t o do t h e

job s a t i s f a c t o r i l y , you w ill need a d r i l l gage. T his gage

i s u sed t o check th e an g le and l e n g t h o f th e l i p s of the

d rill. I n m aking t h i s g ag e, you w i l l n o t o n ly g a i n a t o o l

o f y o u r own, b u t y o u w i l l h a v e c o m p l e t e d o n e o f t h e p r o j e c t s

you a re r e q u i r e d to make. A lso, you w i l l g a in s k i l l s in the

u s e o f t o o l s t h a t a r e new t o you* S t a r t now w i t h t h e i d e a

t h a t when you c o m p l e t e y o u r c o u r s e i n m a c h in e sh o p you w i l l

have a k i t of u se fu l, inex p en siv e to o ls *

A. DIRECTIONS: The f o l l o w i n g d i r e c t i o n s w i l l a s s i s t y o u

i n m aking a d r i l l gag e* (See b l u e p r i n t o f d r i l l gage # 1 .)

1* How t o p r e p a r e s t o c k f o r l a y o u t .

a. Cut o f f a p ie c e of co ld r o lle d s t e e l l / 8 M x

1 l / 2 H x ij. l / 2 M w i t h t h e h a n d h a c k s a w .

b* G r i p work i n b e n c h v i s e , file to len g th , and

s q u a r e up e n d s ,

c* Draw f i l e one s i d e t o a s m o o th f i n i s h a n d a p p l y

l a y o u t dye*

2* How t o l a y o u t t h e d r i l l g a g e *
 3
a. M e a s u r e i n 3/ V * f r o m o n e s i d e and s c r i b e l i n e

AB a s p e r b l u e p r i n t .

b. M easure i n 3 / V from th e e n d and m ark p o i n t C

w ith the s c r i b e r .

c. S e t p r o t r a c t o r a t 59°» l i n e up arm o f p r o t r a c ­

t o r w i t h p o i n t C, and s c r i b e l i n e CB.

3* How to cut t h e g a g e to s h a p e *

a. G r i p w ork i n b e n c h v i s e and saw o u t p o r t i o n n o t

n e e d e d w i t h h a n d h ack saw, l e a v in g a p p r o x im a te ly

l / 32w o f m a te r ia l alo n g the l i n e s to p reserv e

lay o u t.

b. Hough f i l e to sc rib e d lin e w ith a coarse file .

c. F in ish f i le w ith a sin g le c u t sm ooth f i l e . Use

a m aste r eheck gage d u rin g t h is o p e ra tio n as a

double check to o b t a i n th e c o rre c t an g le.

ij-. How t o m a r k t h e g r a d u a t i o n s on t h e g a g e .

a. Clam p g a g e t o a n a n g l e p l a t e w i t h l i n e BC

p a r a l l e l to the surface ta b le . U se a ,fC?f c l a m p

for th is o p eratio n .

b. U sing a s u r f a c e g a g e , s c r i b e on e l i n e l / 8 ” from

BC a n d p a r a l l e l t o BC.

c. S crib e a second l in e l / l f w f r o m BC a n d p a r a l l e l

t o BC.

d. R evolve th e an g le p l a t e w i t h gage a t t a c h e d 90°

on t h e s u r f a c e tab le.
 e. S c r i b e 15 g u id e l i n e s l / l 6n a p a r t as p e r b l u e ­

p rin t; guide l i n e s s h o u l d be p e r p e n d i c u l a r t o

lin e BC.

f. S t a m p BRILL GAGE on t h e t o o l w i t h m e t a l s t a m p s .

B. ACTIVITY ASSIGNMENT: Work y o u s h o u l d d o t o beco m e

p r o f i c i e n t i n th e use of hand t o o l s .

1. Make a d r i l l g a g e f o r y o u r t o o l k i t as d i r e c t e d .

2. Sharpen a d r i l l and check i t w ith your gage.

C. EVALUATION: Sam ples o f c h e c k -u p s u s e d t o e v a l u a t e y o u r

w ork.

1. PRECISION DEVICES: Use o f e x a c t i n s t r u m e n t s t o c h e c k

your w ork.

a. Check d im e n s io n s w i t h a s t e e l r u l e .

b. Check t h e a n g le w i t h m a s t e r check g a g e .

2. TRUE-FALSE: P lace an X i n c o r r e c t space f o r answ er.

T F
a. ( )( ) You s h o u l d t a k e 3 5 b o I(.0 s t r o k e s p e r

m in u te when sa w in g m a t e r i a l l / 8 M t h i c k

w i t h hand hack saw.

b. ( )( ) You s h o u l d r e m o v e s h a v i n g s f r o m t h e f i l e

by rap p in g i t on t h e v i s e .

c. ( )( ) You s h o u l d k e e p t h e s u r f a c e p l a t e

covered a t a l l t i m e s when n o t i n u s e .
 5
3* IDENTIFICATION: P l a c e name o f t o o l i n s p a c e p r o v i d e d .

a
 6

■ALL D / V / S / a z V S AAAM T

O /S / jL L G A G S

4 *»

i.

DETAtL D&AMMG- ■Sh o p jo b n a 1

S C A L E -EULJL D & / C L G A G Z
31U £ P % / m T t
 7

CHAPTER 2 . DRILL DRIFT

HOW TO FABRICATE A TOOL TO REMOVE DRILLS AND
CHUCKS FROM THE SPINDLE OF THE DRILL PRESS

In ju rie s r e s u l t from u se o f im proper t o o l s . The

d rill d rift is th e p r o p e r t o o l t o be u s e d i n rem oving t a p e r

shank d r i l l s , ream ers, chucks, and o th e r s p e c i a l t o o l s from

th e sp in d le of the d r i l l p r e s s . Make a d r i f t t o p r e v e n t

tim e-consum ing t r i p s t o t h e t o o l room, and u se th e tim e

w o rk in g on y o u r p r o j e c t s . The t e a c h e r w i l l r e c o g n i z e i n y o u

a p e r s o n who i s i n d u s t r i o u s a n d o n e who c a n a c c e p t a s s i g n ­

m ents o t h e r th a n r o u t i n e p r o j e c t s . T h i s p r o j e c t may b e made

in l i e u of the f i r s t p r o je c t, the d r i l l gage; how ever, you

w i l l hav e a n eed f o r b o t h t o o l s i n t h e m achine shop.

A. DIRECTIONS: P r o c e d u r e f o r m aking a d r i l l d rift. (See

blue p r i n t of d r i l l d r i f t # 2 .)

1. How t o p r e p a r e sto ck fo r lay o u t.

a. S elect sto ck . Use l / V ’ x l ” x 6 1 3 / l 6 n c o l d

ro lle d steel.

b. C u t m a t e r i a l t o l e n g t h w i t h h a n d h a c k sa w .

c. G rip work i n v i s e , file to len g th .

d. Draw f i l e one s i d e t o a sm ooth f i n i s h and ap p ly

lay o u t dye.

2. How t o l a y o u t t h e d r i l l d r i f t .

a. L o c a t e c e n t e r o f 3 / l 6 l! r a d i u s a n d p r i c k p u n c h
 where l i n e s in te rse ct.

b. S e t d i v i d e r s to r e q u i r e d r a d i u s and s c r ib e arc.

c. L o c a te c e n t e r o f h o l e t o be d r i l l e d i n o p p o s i t e

end and p r i c k punch w here l i n e s in te rse c t.

d. S cribe a sh o rt lin e 2 l/V * i n from th e same e n d .

e. S cribe lin e to form a n g u la r sid e as p e r b l u e p r i n t .

f. S e t d i v i d e r s a t 1 1 /V * r a d i u s a n d s c r i b e l a r g e

arc on t h e e n d .

3. How t o shape a n g u la r s id e .

a. G rip work i n th e v i s e .

b. Saw o f f a n g u l a r s i d e w i t h h a n d h a c k sa w , l e a v i n g

1/ 3 2 h o f m a t e r i a l a l o n g t h e l i n e to p re s e rv e

lay o u t.

c. Rough f i l e to lin e w ith b a sta rd cut f i l e .

d. Rough f i l e rad iu s on edge a s p e r draw ing .

e. F in ish f i l e r a d i u s w i t h s i n g l e c u t sm ooth f i l e .

I4.. How t o d r i l l the h o le.

a. C enter punch lo c a tio n o f h o le .

b. T r a n s f e r work t o t h e d r i l l p r e s s and g r i p work

in d r i l l vise.

c. D r i l l h o l e w i t h 1 / I 4." d r i l l .

d. C o u n tersin k h o le j? /l6" x 82°.

5. How t o c a s e h a r d e n t h e d r i l l d rift.

a. T ra n sfe r the d r i f t to th e fo rg e.

b. Heat slo w ly to c h e rry red .

 9
c. Immerse i n "K asen ite" o r s im ila r a g e n t.

d. Reheat to c h e rry re d .

e. Quench d r i f t in o i l o r w ater.

B. ACTIVITY ASSIGNMENT: Work t o b e d o n e i n c l a s s .

1. Make a d r i l l d r i f t as d irected .

2. C h e c k o t h e r t o o l s t o d e t e r m i n e why t h e y w o u l d n o t b e

s u i t a b l e f o r work done by t h e d rift.

EVALUATION; T e c h n iq u e s t o e v a l u a t e y o u r work.

1. U se d r i l l d r if t to remove a d r i l l f r o m a t a p e r e d

sleeve.

2. PRECISION DEVICES: U se o f e x a c t i n s t r u m e n t s t o

c h e c k work.

a. U se a s t e e l r u l e to check dim ensions.

b. Use p r o t r a c t o r t o c h e c k a n g l e .

3. TRUE-FALSE: P lace an X in c o rr e c t space f o r answ er.

T F
a. ( )( ) You s h o u l d u s e a d r i l l d rift t o remove

ta p e r shank d r i l l s from t h e sp in d le of

the d r i l l p re s s .

b. ( )( ) You s h o u l d u s e c u t t i n g o i l o n t h e d rill

when d r i l l i n g steel.

c. ( )( ) You s h o u l d h o l d t h e w o r k w i t h y o u r h a n d

to d r i l l a l/!fM h o le.
ij.. RATING SCALE: P lace an X in th e s p a c e s f o r w hich

you q u a lif y .

a. ( ) You u s e d h a n d h a c k saw t o c u t m a t e r i a l t o
len g th .

b. ( ) You u s e d a s c r i b e r t o make l a y o u t l i n e s .
c. ( ) You u s e d a p r i c k p u n c h t o m a r k l a y o u t l i n e s .
d. ( ) You u s e d a c e n t e r p u n c h t o m a r k l o c a t i o n o f
hole.

e. ( ) You u s e d a d r i l l v i s e t o h o l d w o r k f o r d r i l l

ing.

f . ( ) You u s e d c u t t i n g o i l o n d r i l l w h i l e d r i l l i n g

h o le.

( ) T o tal.
 11

fill
SECTION A-A

x0 c r # / £ o e A w / M r S h op JOB ^/2 ?.
o e / u D £ / ^ r
I S C ^ £ - a c t/ e A w n r /* s z
 12

CHAPTER 3 . COLD CHISEL

HOW TO PORGE A TOOL TO CUT AND SHEAR METAL

O b ta in good r e s u l t s b y d o in g th in g s r i g h t. The r i g h t

to o l to use for d ressin g , sh ap in g , and c u ttin g m e ta l i s the

cold c h i s e l . The c o l d c h i s e l may a l s o b e u s e d f o r s h e a r i n g

p in s, b o lts , and s h e e t m e t a l . R u sted body r i v e t s and b o l t s

t h a t a r e s t u b b o r n t o rem ove become e a s y to re m o v e i f you

s h e a r them w i t h t h e c o l d c h i s e l and d r i v e them o u t w i t h a

d r i f t punch. (P ro je c t #7)

You w i l l b e r e q u i r e d t o do o n l y o n e f o r g e p r o j e c t .

T h is one f u l f i l l s th a t req u irem en t. E x p e r i e n c e w i l l be

gain ed i n fo rg in g , h ard en in g , and te m p e rin g o f t o o l s t e e l .

The c o l d c h i s e l w i l l be a h a n d y t o o l t o h a v e i n y o u r t o o l

k it.

A. DIRECTIONS: S t e p s t o g u i d e y ou i n m aking a c o l d c h i s e l .

(See b l u e p r i n t o f c o l d c h i s e l # 3 . )

1. How t o o b ta in the c o r r e c t m a t e r i a l .

a. G e t l / 2 w c h i s e l s t e e l fro m s t o c k room.

b. M easure o f f 6" from t h e e n d an d m ark w i t h

scrib er.

c* Cut o f f m a t e r i a l i n p ow er h a c k saw.

2. How t o f o r g e the c h i s e l ,

a. L ig h t the fo rg e .
(1) P la c e l i g h t e d t o r c h i n th e forge*

(2) Open g a s v a l v e w i d e e n o u g h s o g a s i g n i t e s *

(3) T urn on th e blow er*

(if) R e g u l a t e t o a n e u t r a l f l a m e . CAUTION: STAND

WELL CLEAR OF FURNACE OPENING DURING LIGHT­

ING PROCEDURE.

Heat m e ta l slo w ly to a b r i g h t red*

Shape the c h i s e l .

(1) H old m e t a l i n t h e to n g s a t an an g le to the

a n v il and s t r i k e w ith b e v el b lo w s. B low s

sh o u ld be o nly f a i r l y h a rd to b e g in w ith .

(2) F l a t t e n m a t e r i a l somewhat and t u r n o n e - f o u r t h

turn *

(3 ) H old t h e m a t e r i a l p a r a l l e l to th e face of the

a n v i l and s t r i k e th e s id e w ith u p rig h t blow s.

(if) R e h e a t m a t e r i a l w he n n e c e s s a r y , b u t do n o t

b u r n t h e e n d whe n i t b e e o m e s t h i n *

(5) R o ta te m a t e r i a l from f a c e to sid e, strik in g

f o u r o r f i v e blow s i n e a c h p o s i t i o n , u n til

you o b t a i n d e s i r e d shape*

Anneal th e ch isel to reliev e stra in s c a u s e d by

fo rg in g .

(1) Heat t o c h e r r y red*

(2) C over w i t h sa n d to c o o l slow ly*

H arden th e c h i s e l .
 lif

(1) Heat slo w ly , th o ro u g h ly , and evenly to a

cherry red .

( 2 ) P r e v e n t m e t a l f r o m coming i n c o n t a c t w i t h

a i r b l a s t a s much a s p o s s i b l e . T h is b l a s t

w ill o x id ize th e m e ta l.

( 3 ) Q,uench c h i s e l l w d e e p w h i l e t e m p e r a t u r e i s

risin g ; s t i r th ro u g h ly i n w ater or o i l .

f. Tem per t h e c h i s e l t o make i t tough.

(1) P o l i s h ta p e re d s e c t i o n w ith a b r a s iv e c l o t h .

(2) H old c h i s e l o v e r f o r g e and h e a t shank so

h e a t w i l l flow to f o r g e d en d *

( 3 ) Remove f r o m f l a m e w he n p o i n t b e c o m e s p u r p l e

w ith blu e sp o ts .

g. G rin d the c u ttin g an g le t o 70°•

(1) G rin d s lo w ly t o p r e v e n t l o s i n g th e te m p e r.

( 2 ) H o l d c h i s e l s l i g h t l y c a n t e d a n d move b a c k

and f o r t h a c ro s s th e w h eel.

h. Cham fer h e ad o f c h i s e l .

(1 ) T r a n s f e r work t o l a t h e and g r ip i n th re e jaw

c h u c k w i t h h e a d e x t e n d i n g l w.

(2) Pace th e end s q u a r e .

( 3 ) S e t compound r e s t a t 1 2 ° a n d t u r n c h a m f e r a s

per b lu ep rin t.

(if) Remove f r o m l a t h e *
 15
B. ACTIVITY ASSIGNMENTi Work t o b e p e r f o r m e d i n the

lab o ra to ry .

1* Make a c o l d c h i s e l according to d ir e c ti o n s .

2* C u t so m e p i e c e s of m e ta l w i t h th e c o ld c h i s e l .

3* Study v a rio u s d e s ig n s o f c h i s e l s t h a t m ay b e made

i n t h e shop*

C. EVALUATION: S a m p l e s o f some t y p e s o f c h e c k -u p s w hich

may b e a p p l i e d t o y o u r p r o j e c t *

1* TRUE**FALSE: Put an X i n c o r r e c t spaces f o r answer*

T P
a* ( )( ) Tool s t e e l s h a v e more c a r b o n t h a n m i l d

s t© e l •

b* ( )( ) To h a r d e n s t e e l y o u s h o u l d h e a t i t to a

b r i g h t re d and p la c e it i n a box o f sa n d ,

c. ( )( ) Temper c o l o r s i n d i c a t e tem perature*

2* COMPLETION: W rite i n th e lo n g b la n k s ahead o f th e

ite m s the answ ers t h a t sh o u ld be i n th e s h o r t to k en

b la n k s w i t h i n th e item s*

a* ______________ A nnealing i s the p ro c e ss u sed to

make s t e e l ________.

b* ______ _ __ _ __ T em pering i s d o n e a f t e r ________ •

3* RATING SCALE: P l a c e an X i n th e s p a c e f o r w hich

you q u a lify *
( ) You w o r e g o g g l e s w h e n o p e r a t i n g the g r i n d e r .

( ) You f o l l o w e d p r o c e d u r e o u t l i n e d i n the

d i r e c t i o n s and r e a d b l u e p r i n t .

( ) You c u t m a t e r i a l r e q u i r e d f o r t h e c h i s e l a n d

r e t u r n e d re m a in d e r of m a t e r i a l t o s t o c k r o o m .

( ) You r e h e a t e d m a t e r i a l o f t e n when f o r g i n g .

( ) You t u r n e d o f f g a s b e f o r e t u r n in g blow er o f f

when s e c u r i n g t h e forge.

) T o tal
 1

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 18
CHAPTER I4.. BUSHING REMOVER
HOW TO MAKE A TOOL TO REMOVE WORN BUSHINGS

W a t c h t h a t m e t a l come p e e l i n g o f f I Making a b u s h i n g

rem over p ro v id e s an o p p o r tu n ity to operate the l a t h e . Many

new e x p e r i e n c e s a r e in sto re f o r you i n m aking t h i s p r o j e c t .

Your v o c a b u la r y w i l l i n c r e a s e as you use term s c o n n ec te d

w i t h o p e r a t i o n s p e rfo rm e d on th e l a t h e . The b u s h i n g r e m o v e r

w i l l come i n h a n d y w h e n y o u a r e k n o c k i n g o u t w o r n b u s h i n g s

and b e a rin g s from p a r t s on t h a t Hj a l o p y . ” A few o f th e o p e ra ­

t i o n s y o u w i l l l e a r n a r e m o u n t i n g work i n t h e c h u c k , facin g ,

c e n t e r d r i l l i n g , m o u n tin g work b e tw e e n c e n t e r s , and s tr a ig h t

tu rn in g . You w i l l h a v e y o u r e y e s a n d f i n g e r s to use tom orrow

i f you obey your s a f e t y r u l e s in o p e ra tin g th e l a t h e . Com­

p l e t i o n o f the b u sh in g rem over s a t i s f i e s one r e q u i r e m e n t f o r

lath e p ro je c ts.

A. D I RECTIONS; S u g g e s t i o n s o n - h o w t o ma k e a b u s h i n g r e -

m over. (See b l u e p r i n t of b u s h in g rem o v e r # 7 » )

1. How t o d r e s s f o r o p e r a t i n g t h e l a t h e safely .

a. Cut h a i r s h o r t enough t h a t i t w i l l n o t be

d an g lin g .

b. R oll your sle e v e s above th e elbow .

e. Remove n e c k t i e s or o th e r d an g lin g c lo th in g .

d. Remove a l l r i n g s , b rac ele ts, and w r is t w atch es.

©• Wear g o g g l e s or a faee s h ie ld i f th ere i s

danger of fly in g c h ip s.

How t o obtain m a te ria l.

a. Get a p ie c e o f 1" d i a m e t e r c o l d - r o l l e d s t e e l

from th e s to c k r a c k .

b. C u t o f f s t o c k 5 l / 8 ” l o n g on p o w e r h a c k s a w .

How t o p r e p a r e s t o c k f o r m o u n t i n g b e t w e e n c e n t e r s .

a. P lace sto ck in th ree jaw u n i v e r s a l chuck on t h e

la th e and face l / l 6M o f f each end. S tock sh o u ld

th e n m easure 5H lo n g .

b. T r a n s f e r work t o b e n c h v i s e ; la y o u t and c e n te r

punch c e n te rs o f b o th ends.

c. Use c e n t e r h e a d fr o m c o m b i n a t i o n s e t t o l a y o u t

cen ters•

d. P lace d r i l l chuck c o n ta in in g s iz e WE ” c e n t e r

d rill in the h ead sto ck s p in d le .

e. P lace hardened c e n te r i n t a i l s t o c k sp in d le.

f. P la c e s to c k betw een c e n t e r d r i l l and h a rd e n ed

cen ter; h o ld sto ck w ith l e f t hand.

g. T urn on th e l a t h e and f e e d th e s to c k tow ard th e

h e a d s t o c k by t u r n i n g the t a i l s t o c k handwheel to

th e rig h t. Use c u t t i n g o il on t h e d rill.

h. C o u n tersin k b o th ends as p e r b l u e p r i n t .

How t o m o u n t s t o c k b e t w e e n c e n t e r s .

a. Remove d r i l l chuck, p la c e facep late on h e a d s t o c k

 20

spin d le, and i n s e r t liv e c e n te r in the s p in d le ,

b. Check a l i g n m e n t o f c e n t e r s .

c. P l a c e l a t h e dog on t h e s t o c k .

d. L u b ricate tailsto ck c e n te r w ith w hitele a d .

e. P lace s t o c k betw een c e n t e r s and t i g h t e n tail-

stock s p in d le .

5* How t o tu rn b u sh in g rem over to s i z e .

a. T u rn o u ts id e d iam eter o f stock to 3 / V f « Use

ro u n d n o se d t o o l m ounted s l i g h t l y above c e n t e r

and f e e d tow ard th e h e a d s to c k .

b. Lay o u t l i n e a r o u n d t h e sto c k 2 M from th e end,

u sin g herm ap h ro d ite c a l i p e r s . R eplace th e dog

on t h i s e n d and m ount w o rk b e tw e e n c e n t e r s .

e. T u r n w o r k down t o 1 1 / 1 6 ” i n d i a m e t e r u p t o t h e

lin e 2 H from t h e e n d .

d. M a rk o f f 1 ” s e c t i o n f r o m t h e s h o u l d e r a n d t u r n

re m a in d e r o f the s to c k t o 5/ 6 M d i a m e t e r .

e. M a rk o f f l n f r o m s h o u l d e r a n d t u r n r e m a i n d e r o f

w o r k t o 1/ 2 ” d i a m e t e r .

f . P lace r i g h t hand fa c in g to o l i n h o ld e r and tu rn

a ll s h o u l d e r s 9 0 °*

g. Check a l l d im e n s io n s f o r p o s s i b l e errors.
 21

C. ACTIVITY ASSIGNMENT: Work f o r y o u t o a c c o m p l i s h i n mak­

ing a bushing rem over.

1. Make a b u s h i n g rem over a c c o rd in g t o d i r e c t i o n s .

2. L i s t p ro b le m s you e x p e r i e n c e d i n m aking t h e b u s h in g

r e m o v e r ; make a l i s t of re la te d m aterials th a t give

th e answ ers to th e s e p ro b lem s.

D. EVALUATION: Sam ples o f so m e ty p e s o f c h e c k -u p s w hich

may b e u sed t o e v a lu a te your w ork.

1. PRECISION DEVICES: U se o f e x a c t i n s t r u m e n t s t o

check yo u r w ork.

a. Check l e n g t h o f w ork w i t h s t e e l ru le.

b* Check d i a m e t e r of work w i t h o u t s i d e c a l i p e r s .

2. BEST ANSWER: P lace th e number of th e b e s t answ er

in the p a re n th e s e s .

a* ( ) To m e a s u r e w o r k o n t h e l a t h e a c c u r a te ly you

should use: (1 ) c a l i p e r s . (2 ) r u l e . (3 )

m icro m eter. (If) t a p e m e a s u r e .

b. ( ) To l u b r i c a t e th e t a i l s t o c k c e n t e r you sh o u ld

use: (1 ) w h ite l e a d . (2 ) lu b ric a tin g o i l .

(3 ) c u ttin g o il. (if) t u r p e n t i n e ,

c*. ( ) For b e st r e s u lts you sh o u ld l u b r i c a t e the

lath e: ( 1 ) oncea week. (2 ) tw ice a day.

( 3 ) once a m onth* (if) o n c e a d a y .

 22

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 23

CHAPTER 5 . CENTER PUNCH

HOW TO MAKE A TOOL FOR LAYING OUT HOLES TO BE DRILLED

A good c e n t e r punch i s an in d is p e n s a b l e t o o l i n th e

m achine shop. The c e n t e r p u n c h i s u s e d t o m a r k c o r r e c t l y

the lo c a tio n s o f h o le s to be d r i l l e d and a s s i s t s you i n

s ta r tin g th e d r i l l p ro p erly . You m ay u s e t h e c e n t e r p u n c h

t o m a r k a d j o i n i n g p a r t s i n a n a s s e m b l y t o make s u r e y o u r e ­

assem ble th e p a r t s i n th e c o r r e c t m anner. I f you have a

c e n t e r p u n c h o f y o u r own, y o u w i l l n o t h a v e t o w a i t i n l i n e

at t h e t o o l room i n o r d e r t o o b t a i n a p u n c h . A lso, man y

t i m e s t h e p u n c h e s i n t h e t o o l room become d u l l a nd c a u s e

i n a c c u r a t e work. You w i l l n o t o n l y h a v e a g o o d t o o l t o a d d

to your k i t , b u t y o u w i l l l e a r n t o do k n u r l i n g a n d t a p e r

t u r n i n g on t h e l a t h e b y m ak in g t h e c e n te r punch.

A. DIRECTIONS; P ro c e d u re f o r m aking a c e n t e r punch. (See

B lu e p rin t of c e n te r punch # 5 . )

1. How t o select stock.

a. U se d r i l l r o d 3 / 8 ” d i a m e t e r x Ij. 1 / 2 " l o n g .

b. Cut s t o c k t o l e n g t h w i t h h a n d h a c k saw.

2. How t o c e n t e r d r i l l t h e e n d o f t h e stock.

a. P lace sto c k in th re e jaw u n i v e r s a l c h u c k on t h e

l a t h e and f a c e one end.

b. P lace d r i l l chuck c o n ta in in g s iz e "E" c e n t e r

 d rill in the t a i l s t o c k sp in d le.

c. Peed the d r i l l in to the sto c k u n t i l c e n te r hole

m e a su re s 3/ l 6 " a c r o s s .

How t o m ake t h e b o d y o f t h e p u n c h .

a. A d j u s t t h e work i n c h u c k w i t h d r i l l e d end e x te n d ­

in g 3 1/ 2 "

b. Remove t h e d r i l l chuck from t a i l s t o c k spindle

and p la c e hardened c e n t e r in th e sp in d le.

c. A djust t a i l s t o c k so i t w ill su p p o rt d r i l l e d end

o f t h e w ork.

d. Set lath e fo r slow s p e e d and p l a c e k n u r l i n g t o o l

in to o l h o ld er.

e. K nurl s e c t i o n as p e r b l u e p r i n t ; a l l o w 5j/ i 6"

s t o c k on t h e end f o r rem o v in g t h e c e n t e r h o l e .

f. A p p ly c u t t i n g o i l f r e e l y on t h e w ork d u r i n g

k n u rlin g o p eratio n .

g. T u r n down r e m a i n d e r o f w o r k t o d e p t h o f t h e k n u r l .

h. Cut o f f d r i l l e d s e c t i o n and ch am fer end l / l 6 " x

k-5°-

i. Remove t h e p u n c h f r o m t h e c h u c k .

How t o make t h e p o i n t .

a. P lace s o f t b ra s s around k n u rle d s e c tio n and p la c e

in chuck w ith 2 " e x te n d in g out o f th e chuck.

b. S e t c o m po u n d r e s t t o t u r n t a p e r 2 1 / 2 " p e r f t .

T his i s 96° to th e r i g h t , r e a d in g from th e h e ad -

 25

sto ck side.

c. Roug h a n d f i n i s h t u r n t a p e r , u s i n g round nose

t o o l g round to form f i l l e t at th e sh o u ld er. Set

t o o l on c e n t e r f o r t a p e r t u r n i n g .

d. S e t compound r e s t a t 120° to th e r i g h t and t u r n

th e 60° p o in t.
e. P o lish w ith fin e abrasive c l o t h and o i l .

5. How t o h a r d e n a n d p o l i s h t h e p o i n t .

a. T ra n s fe r punch to f o r g e and h e a t th e p o in t to

ch erry red.

b. Quench i n o i l o r w a t e r .

c. Draw t e m p e r t o straw c o lo r.

d. R eplace punch i n t h e chu ck on the la th e and

p o lis h w ith f in e ab rasiv e c lo th .

B. ACTIVITY ASSIGNMENT: Work t o b e d o n e i n t h e shop.

1. Make a c e n t e r p u n c h a c c o r d i n g t o d irectio n s.

2. Make a c e n t e r p u n c h a c c o r d i n g t o d i r e c t i o n s , u sing

o ctag on to o l s t e e l in s te a d of d r i l l rod; om it th e

k n u rlin g o p eratio n .

C. EVALUATION: T e c h n i q u e s t h a t may b e u s e d t o check your

progress.

1. PRECISION DEVICES: Use o f e x a c t i n s t r u m e n t s t o c h e c k

work:
a. Check a l l d im e n s io n s w i t h s t e e l r u l e .

b. Check 6 0 ° p o i n t w i t h c e n t e r g a g e .

TRUE-FALSE: P lace an X in c o rr e c t space f o r answ er.

T F
a. ( ) ( ) You s h o u l d u s e h i g h s p e e d f o r k n u r l i n g

o p e ratio n s.

b. ( )( ) You s h o u l d l e a v e a p o r t i o n o f t h e p u n c h

s o f t to absorb shock.

c. ( )( ) You s h o u l d u s e a c e n t e r p u n c h t o m a r k

a l l h o l e s t o be d r i l l e d .

RATING SCALE: P la c e an X i n e a c h space f o r w hich

you q u a li f y .

a. ( ) You w o r e g o g g l e s w h e n o p e r a t i n g t h e g r i n d e r .

b. ( ) You u s e d d r i l l ro d f o r m aking th e punch.

c. ( ) You s e t t h e l a t h e on slo w s p e e d f o r k n u r l i n g

o p eratio n .

d. ( ) You h e a t e d p u n c h s l o w l y t o p r e v e n t i n j u r y t o

th e m etal.

e. ( ) You a p p l i e d c u t t i n g o i l f r e e l y on w ork d u r i n g

k n u rlin g o p eratio n .

( ) T o tal.
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 28

CHAPTER 6 . PRICK PUNCH

HOW TO MAKE A TOOL FOR MARKING SCRIBED OR LAYOUT LINES

Tim e i s w a ste d i f you c a n n o t s e e y o u r l a y o u t l i n e s

a f t e r t h e y a r e made. You n e e d a g o o d p r i c k p u n c h t o u s e i n

m arking l a y o u t l i n e s in order th a t t h e y may b e s e e n e a s i l y .

P r i c k p u n c h e s b o r r o w e d f r o m t h e t o o l room are som etim es d u ll,

and y o u spend y o u r tim e s h a r p e n i n g them . I f y o u h a v e made

t h e c e n t e r p u n c h , y o u a r e n o t r e q u i r e d t o make t h e p r i c k

punch. However, y o u r t o o l k i t w i l l n o t be c o m p le te w i t h o u t

th e p r ic k punch. I n m aking t h e p r i c k p u n c h , you h av e an

o p p o rtu n ity to im prove s k i l l s t h a t were u s e d i n m aking t h e

c e n te r punch.

A. DIRECTIONS: S te p s t h a t w i l l a i d you i n m aking a p r i c k

punch. (See b l u e p r i n t o f p r i c k punch #6 .)

1. How t o s e l e c t the sto c k .

a. U s e d r i l l r o d 3 / 8 ,f d i a m e t e r x If l / 2 M l o n g .

b. C u t s t o c k t o l e n g t h w i t h h a n d h a c k sa w .

2. How t o c e n t e r d r i l l th e end o f th e s to c k .

a. P lace sto ck in th re e jaw u n i v e r s a l c h u c k on th e

lath e and fa c e one en d .

b. P lace d r i l l chuck c o n ta in in g a siz e ME r’c e n t e r

d rill in the t a i l s t o c k spin d le.

c. Feed th e d r i l l in to the sto c k u n t i l c e n te r hole

m e a s u r e s 3 / l 6 ,f a c r o s s .
How t o make t h e b o d y o f t h e p u n c h .

a. A d ju s t th e work i n chuck w ith d r i l l e d end e x ­

t e n d i n g 3 1/ 2 ” .

b. Hemove t h e d r i l l chuck from t a i l s t o c k sp in d le

and p la c e h a rd e n e d c e n t e r i n th e s p i n d l e .

c. A djust t a i l s t o c k so i t w ill support d r i l l e d end

o f t h e work.

d. Set la th e f o r slow speed and p l a c e k n u r l i n g t o o l

in to o l h o lder.

e. K nurl s e c t i o n a s p e r b l u e p r i n t ; allo w

s t o c k on t h e en d f o r re m o v in g t h e c e n t e r h o l e .

How t o make t h e p o i n t .

a. P lace s o f t b r a s s a ro u n d k n u r l e d s e c t i o n and

place in chuck w ith 2 n e x te n d in g o u t o f th e

chuck.

b. S e t compound r e s t to tu r n ta p e r 2 l / 2 ” p e r f t .

T his i s 96° to the r i g h t , r e a d in g from th e h ead -

sto ck sid e.

c. Rough and f i n i s h t u r n t a p e r , u s in g round nose

t o o l on c e n t e r f o r t a p e r t u r n i n g .

d. S e t c o m p o u n d r e s t a t 1 12 l / 2 ° t o th e r i g h t and

t u r n 1|5 ° p o i n t .

How t o h a r d e n a n d p o l i s h t h e p o i n t .

a. T ra n s fe r punch to the fo rg e and h e a t th e p o in t

to ch erry red.
 30

b. Quench i n o i l o r w a t e r .

c. D raw t e m p e r t o straw c o lo r .

d. R e p la c e p u n c h i n t h e c h u c k on t h e l a t h e and

p o lis h w ith fin e ab rasiv e c lo th .

B. ACTIVITY ASSIGNMENT: W ork t o b e d o n e i n t h e shop t o h e l p

you m a s te r t h e o p e r a t i o n s r e q u i r e d i n m aking a p r i c k

punch.

1. Make a p r i c k p u n c h a c c o r d i n g t o d i r e c t i o n s .

2. Sharpen d u ll p r i c k punches i n th e t o o l room.

C. EVALUATION: T e c h n i q u e s t h a t may b e u s e d t o c h e c k y o u r

progress.

1. T e s t h a r d n e s s o f th e p o i n t by m arking la y o u t l i n e s ,

on v a r i o u s t y p e s o f m e t a l .

2. TRUE-FALSE: P lace an X in correct space f o r answ er.

T F
a. ( )( ) You w i l l n e e d a c e n t e r p u n c h a n d a p r i c k

punch in your to o l k i t .

b. ( )( ) You s h o u l d r e m o v e a l l r i n g s a n d w r i s t

w atches b e fo re o p e ra tin g th e la th e .

c. ( )( ) You s h o u l d u s e d r i l l ro d f o r m aking th e

p r ic k punch, because t h i s m a te ria l con­

ta in s in g red ien ts t h a t make i t p o s s i b l e

to harden.
COMPLETION: W rite in th e long b la n k s ahead o f the

item s th e answ ers t h a t s h o u ld be i n th e s h o r t token

b lanks w ith in th e item s.

a. ________________ You s h o u l d n o t c l e a n , o il, or ad­

j u s t a m a c h i n e w hen i t i s ______ .

b. ________________ D r i l l r o d h a s a h i g h ____ con­

ten t.

c. _______________ The c o m p o u n d r e s t is graduated

C
M

to <0
oi ot
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 33
CHAPTER 7 . DRIFT PUNCH
HOW TO MAKE A TOOL FOR REMOVING BOLTS AND RIVETS BY FORCE

That stu b b o rn b o lt or r i v e t c an be rem oved w i t h a

d r i f t p u n c h and a few w e l l c h o se n b lo w s fro m a b a l l p e e n

ha m m er. It i s m uch c h e a p e r t o m ake t h e p u n c h i n c l a s s t h a n

to purchase i t from a su p p ly h o u s e . Y o u r f r i e n d s who w o r k

o n nh o t rods** a n d s c o o t e r s w i l l a p p r e c i a t e a d r i f t punch as

a sm all g i f t fro m you. The d r i f t p u n c h i s n o t a s p e c i f i c

req u irem en t, b u t may b e u s e d a s y o u r c h o i c e o f a r e q u i r e m e n t .

The p u n c h i s designed to s t a n d h e a v y b l o w s a n d may b e u s e d

f o r rem oving th o s e very stu b b o rn p in s , sheared b o lts , and

r i v e t s w ith the heads cut o f f .

A. DIRECTIONS: S u g g e s t i o n s t h a t may b e f o l l o w e d i n m a k i n g

a d r i f t punch. (See b l u e p r i n t o f d r i f t p un ch # 7 . )

1. How t o select stock.

a. O b t a i n 3 / 8 ,r d i a m e t e r d r i l l rod from s to c k r a c k .

b. Cut s t o c k If. l / 2 u l o n g w i t h h a n d h a c k sa w.

2. How t o c e n t e r d rill th e end o f th e stock.

a. P lace sto ck in th re e jaw u n i v e r s a l c h u c k on t h e

l a t h e a n d f a c e one e n d .

b. P lace d rill chuck c o n ta in in g a s iz e nE " c e n t e r

d rill in the t a i l s t o c k sp in d le.

c. Feed th e d r i l l i n t o th e sto c k u n t i l c e n te r hole

m e a s u r e s 3 / l 6 ,f a c r o s s .
 3k
3- How t o make t h e b o d y o f t h e p u n c h .

a. A d j u s t w ork i n t h e c h u c k w i t h d r i l l e d end e x te n d ­

in g 3 1 /2 ” .

b. Remove t h e d r i l l chuck from th e t a i l s t o c k sp in d le

and p la c e h a rd en ed c e n t e r i n the spin d le.

c. 'A d ju s t t a i l s t o c k so i t w i l l s u p p o r t t h e d rilled

end o f t h e w ork.

d. Set lath e on slow sp e e d and p l a c e k n u r l i n g t o o l

in to o l h o ld er.

e. K nurl s e c t i o n a s p e r b l u e p r i n t , allo w in g £ / l 6 n

s t o c k on t h e e n d f o r re m o v in g t h e c e n t e r h o l e .

f. Use c u t t i n g o i l a p p l i e d f r e e l y o n t h e w o r k d u r i n g

th is o p eratio n .

g. T u r n down r e m a i n d e r o f t h e w o r k t o t h e d e p t h o f

th e k n u r l.

h. Gut o f f d r i l l e d s e c t i o n and cham fer end l / l 6 ” x

k$°.
i. Remove t h e p u n c h f r o m t h e c h u c k .

1]_. How t o make t h e p u n c h s e c t i o n .

a. P lace s o f t b r a s s around k n u rled s e c tio n and p lace

i n chuck w ith 2 1 /2 ” e x te n d in g ou t o f th e chuck.

b. Pace th e end to c o r r e c t le n g t h .

c. R ou g h a n d f i n i s h tu r n punch end, u s in g round nose

t o o l sh a rp e n e d to form f i l l e t at sh o ulder.
 35?

d. P i l e m achined s u r f a c e s l i g h t l y t o remove t o o l

m arks.

e. P o lis h w ith fin e ab rasiv e c l o t h and o i l .

If. How t o h a r d e n a n d p o l i s h t h e p u n c h .

a. T ra n sfe r punch to th e f o r g e and h e a t pun ch end

to c h erry red .

b. Quench i n w a t e r o r o i l .

c. Draw t e m p e r t o straw c o lo r.

d. R eplace i n l a t h e and r e p o lis h .

B. ACTIVITY ASSIGNMENT: Work y o u s h o u l d a c c o m p l i s h i n t h e

s h o p t o m ake y o u r d r i f t p u n c h .

1. Make a d r i f t p u n c h a s d i r e c t e d and ad d i t to your

to o l k it.

2. Check d e s i g n s o f d r i f t p u n c h e s i n several to o l

catalo g s; make a d r i f t p u n c h o f a d i f f e r e n t d e s i g n .

C. EVALUATION: Some t y p e s o f c h e c k - u p s w h i c h may b e a p p l i e d .

1. Check a l l dim ensions a c c o rd in g to the b lu e p r in t.

2. TRUE-FALSE: P lace an X in c o rre c t space f o r answ er.

T F
a. ( )( ) In o rd e r to hard en the punch, you sh o u ld

heat i t t o a c h e r r y r e d and quench i t in

o il o r w ater.
b. ( )( ) I n o r d e r t o te m p e r t h e punch, you

should h a rd e n i t first.

c. ( )( ) You s h o u l d w e a r g o g g l e s w h e n t h e r e is

d a n g e r o f c h i p s f l y i n g o f f t h e work.

MATCHING: P l a c e t h e number o f t h e a r t i c l e in the

p aren th eses before the s ta te m e n t t o w hich i t b e lo n g s .

a. ( ) F ile 1. B a ll peen

b. ( ) D rill 2. Tang

c. { ) C hisel 3. T eeth

d. ( ) H a c k saw ij.. A lloy

e. ( ) Tap 5. Mushroom h e a d

f . ( ) Hammer 6. Cap

7. L ip c le a r a n c e

8. Plug
 37

N o r n :# /)& £ > £ w pu m c#
£ M O -D P P W
s p e p w cox. o p CH PM P£& ~ X4 S ~

kt

D £ D 9 /t 0 & 9 W /M G S w a p J o b /v 9 7
D /z /r r p o a j c h
! 5 C P £ £ ~ S ^ C /L C 3 lV £ P & W 7 rtZ 7
 38

CHAPTER 8 . NAIL SET

HOW TO MAKE A TOOL TO SET NAILS BELOW THE SURFACE INTO
WHICH THEY HAVE BEEN DRIVEN

"Wood b u t c h e r s " , a tte n tio n .1 You w i s h t o make t o o l s

t h a t c a n b e u s e d i n y o u r wood s h o p c l a s s e s a n d i n t h e home

work sh op. A good n a i l set is an in d is p e n s a b le t o o l f o r you,

and i t c a n b e made i n t h e m a c h i n e s h o p . You n o t o n l y h a v e a

to o l upon co m p letio n , b u t y o u g a i n t h e same s k i l l s and ex­

p e r i e n c e s y o u r c l a s s m a t e s g a i n i n m aking a c e n t e r p u n c h o r

p r i c k punch. You " p e n n y w i s e " s t u d e n t s w i l l a p p r e c i a t e

a n o th e r advantage, as th e n a i l s e t c a n b e m ade f o r a f r a c ­

tio n of i t s a c tu a l c ash v alu e. Many s t e p s w i l l b e saved i f

y o u m ake t h e n a i l s e t a s one o f y o u r r e q u i r e d o r e l e c t i v e

p ro je c ts.

A. DIRECTIONS; S t e p s t h a t m ay b e f o l l o w e d i n m a k i n g a n a i l

set. (See b l u e p r i n t o f n a i l set # 8 .)

1. How t o select sto c k f o r the n a i l set.

a. O btain d r i l l ro d 3 /8 " d ia m e te r from r a c k .

b. C u t o f f Ij. 1 / 2 " w i t h h a n d h a c k s a w .

2. How t o c e n t e r d r i l l end o f sto c k .

a. P lace sto ck in th re e jaw u n i v e r s a l c h u c k on t h e

lath e and f a c e one end.

b. P lace d r i l l chuck c o n ta in in g a s iz e "E " c e n t e r

 39
d rill in the t a i l s t o c k sp in d le.

c. Feed the d rill in to the sto c k u n t i l c e n te r hole,

m e a s u r e s 3 / l 6 ,, a c r o s s .

3. How t o make t h e b o d y o f t h e p u n c h .

a. A d j u s t t h e work i n ch u ck w i t h d r i l l e d end e x ­

t e n d i n g 3 1 / 2 ft'.

b. Remove t h e d rill chuck from t a i l s t o c k s p in d le

and p la c e hardened c e n te r i n th e s p in d le .

c. A djust t a i l s t o c k so i t w i l l su p p o rt d r i l l e d end

o f t h e w ork.

d. S e t l a t h e f o r slow s p e e d an d p l a c e k n u r l i n g t o o l

in to o l h o ld er.

e. K nurl s e c t i o n as p e r b l u e p r i n t , allo w in g 5 /l6 "

s t o c k on th e end f o r rem oving th e c e n t e r h o le .

f. Use c u t t i n g o i l a p p l i e d f r e e l y on t h e w ork

d uring t h i s o p eratio n .

g. T u r n down r e m a i n d e r o f w o r k t o d e p t h o f t h e k n u r l .

h. Cut o f f d r i l l e d s e c t i o n a n d c h a m f e r e n d l / l 6 tt x

V 5.
i. Remove t h e s t o c k f r o m t h e c h u c k .

I4.. How t o make t h e t a p e r a n d c o n c a v e p o i n t .

a. P la c e s o f t b ra s s around k n u rle d s e c t i o n and p la c e

in chuck w ith 2 H ex te n d in g out of th e chuck.

b. S et 3 /3 2 n r a d i u s t o o l on c e n t e r and concave end

as p er b lu e p rin t.
 IfO
c. S e t compound r e s t a t 96° to the r i g h t , reading

from th e h e a d s to c k s id e . T his i s p ro p e r an gle

f o r t u r n i n g t a p e r 2 l / 2 tf p e r f t .

d. S e t ro u n d n o se t o o l on c e n t e r f o r t u r n i n g th e

tap er. Tool s h o u ld be g ro u n d w ith 1 / 3 2 ” r a d i u s .

e. Rough an d f i n i s h tu r n ta p e r e d end to d e s ir e d

size.

f. P i l e m ach in ed s e c t i o n s l i g h t l y t o rem ove t o o l

m arks. U se m i l l f i l e .

5. How t o p o l i s h a n d h a r d e n p o i n t .

a. P o lish n a il s e t w ith f in e ab rasiv e c lo th and o i l .

b. T ransfer n a il set to the fo rg e , and h e a t p o int

to cherry red.

c. Quench i n o i l o r w ater.

d. Draw t e m p e r b y r e h e a t i n g t o straw c o lo r.

e. R eplace in l a t h e and r e p o l i s h w ith f i n e a b ra s iv e

c l o t h and o i l .

B. ACTIVITY ASSIGNMENT: Work t o b e a c c o m p l i s h e d i n c l a s s i n

s o l v i n g p ro b le m s i n v o l v e d i n m aking a n a i l se t.

1. Make a n a i l se t as d ire c te d .

2. U s e same d i r e c t i o n s a n d make n a i l s e t s t h a t may b e

used f o r s e ttin g larg er n a ils.

 k-1
G. EVALUATION: Some t e c h n i q u e s t h a t may b e u s e d t o c h e c k

y o u r w ork.

1. PRECISION DEVICES: U se o f e x a c t i n s t r u m e n t s t o

c h e c k w ork:

a. Check d im e n s i o n s w i t h s t e e l r u l e .

b. Check r a d i u s w i t h r a d i u s g a g e .

2. COMPLETION: W rite i n th e lo n g b la n k s ahead o f th e

item s th e answ ers t h a t should be in th e s h o r t to k en

b la n k s w ith in the item s.

a. You s h o u l d u s e a ( a n ) ______ t o

draw a r c h e s and c i r c l e s .

b. ___________ You s h o u l d m a r k h o l e s t o be

d r i l l e d w i t h a ( a n ) ______ .

3. RATING SCALE: Put check in a p p ro p ria te square

op p o site each q u a lity .

1-poor 2 -fair 3-good J^ -exc 11 ’ t score

L ength

Taper

R adius

K nurl

A ppearance
T o tal

If.. Set several n a ils to check toughness of th e to o l.

 42

C h A M tt# >7 X 4 S
r t< r r £ : a/ s e t
£ A ' D ~ D g & U J T Z M t tJ e
£Tfi=,*>W C O L O /S .

D f r /9 7 1 D & A W /A /G S H O P %JOB N $ <?

S C # L £ - r & jL jC aCU EP& tH T >- ^
 4-3
CHAPTER 9 . PLUMB BOB
HOW TO MAKE A TOOL TO CHECK VERTICAL STRUCTURES TO
DETERMINE I P THEY ARE PERPENDICULAR

Do y o u w i s h t o make a Hs w e l l ,! p r e s e n t f o r some o n e

y o u know i n t h e b u i l d i n g t r a d e s ? A p l u m b b o b w i l l f,f i l l the

b ill.” I f n o t, you w i l l need t h i s little to o l to check the

y a rd fe n c e you a r e g oing to b u i l d t o see i f it is p erp en d ic­

u lar. Any v e r t i c a l s t r u c t u r e , o l d o r new, c a n be c h e c k e d

w i t h t h e plumb bo b t o d e t e r m i n e i f it is a t r i g h t an g les to

its fo u n d atio n . New s k i l l s w i l l be u se d and o ld s k i l l s

re v ie w e d and im proved i n the m achining of t h i s p r o j e c t .

Some s t u d e n t s f i n d a read y m arket f o r th e s e t o o ls sin c e th ey

can s e l l them below p r i c e s charged elsew h ere.

A. DIRECTIONS: H i n t s t h a t w i l l g u i d e y o u i n m ak in g a plumb

bob. (See b l u e p r i n t o f plum b bob # 9 « )

1. How t o s e l e c t the m a t e r i a l .

a. O b tain 1 H d iam ete r c o ld r o l l e d s t e e l from r a c k .

b. C u t s t o c k I4. l / V lo n g i n power h a c k saw.

2. How t o d r i l l t h e tw o h o l e s .

a. P lace m a te ria l i n three jaw u n i v e r s a l ch u ck a n d

face th e end.

b. Remove f r o m c h u c k ; la y out and c e n te r punch #10

h o le.

c. T r a n s f e r work t o d rill press. D r i l l #10 hole

 th rough c e n te r o f diam eter as p e r b l u e p r i n t,

d. R e tu r n work t o the l a t h e . P lace in th re e jaw

u n i v e r s a l chuck and d r i l l hole to in te rs e c t

the #10 hole a lre a d y d r i l l e d .

3* How t o m a c h i n e s t o c k t o s i z e and k n u rl.

a. R ech u ck work w i t h d r i l l e d e n d e x t e n d i n g 3 l / 2 " .

b. S u p p o rt d r i l l e d end w ith t a i l s t o c k cen ter.

e. Turn m a t e r i a l down t o l 5 / l 6 H d i a m e t e r .

d. P lace k n u rlin g to o l in to o l h o ld e r and k n u rl

se c tio n s as p er b lu e p rin t.

e. T urn r e m a in d e r of m a t e r i a l down t o the d e p th of

th e knurl*

ij.* How t o m a c h i n e the r a d i i .

a* Use r o u n d n o s e c u t t e r b i t s e t a t cen ter lin e of

work t o r o u g h t u r n r a d i u s on l a r g e d iam eter.

U se l o n g i t u d i n a l a n d c r o s s f e e d m a n u a l l y a t same

tim e to rough o u t the r a d i u s . DO HOT ATTEMPT TO

USE AUTOMATIC FEED.

b. Rough t u r n r a d i u s on s m a ll d i a m e t e r i n same

m anner.

c. U se f o r m i n g t o o l g r o u n d t o £ / l 6 !t r a d i u s a n d

fin ish tu rn ra d ii. Set lath e on slo w sp e e d and

use c u ttin g o il.

d. Remove w o r k f r o m c h u c k .

5. How t o t u r n the t a p e r .
 a. P la c e s o f t b r a s s arou nd k n u rle d s e c t i o n and

place i n chuck w ith 1 3 /V f ex ten d in g .

b. S e t compound r e s t for tu rn in g ta p e r . Set a t

108°, r e a d in g from h e a d s to c k sid e.

c. Use r o u n d n o s e c u t t e r b i t s e t a t c e n t e r o f t h e

work f o r tap er tu rn in g .

d. Rough a n d f i n i s h t u r n the tap er.

e. P i l e m a c h in e d s u r f a c e s l i g h t l y w i t h sm ooth f i l e .

f. P o lish w ith fin e a b ra siv e c lo t h and o i l .

B. ACTIVITY ASSIGNMENT; Some l e a r n i n g e x p e r i e n c e s t o i n ­

crease your s k ills in the u se of m ach in es and t o o l s .

1. Make a p l u m b b o b a s d i r e c t e d .

2. Read r e l a t e d m a t e r i a l s e x p l a i n i n g how o r e i s m ade

in to ste e l; s e l e c t p r o c e s s you th in k b e s t and l i s t

s t e p s b y w hich i t i s made.

C. EVALUATION! C h e c k - u p s w h ic h may b e u s e d .

1. PRECISION DEVICES: Use o f e x a c t i n s t r u m e n t s t o check

w ork.

a. Check d i m e n s io n s w i t h s t e e l r u l e .

b. Check r a d i u s w i t h r a d i u s gage.

e. Check a n g l e o f t a p e r w i t h p r o t r a c t o r .

2. RATING SCALE: P la c e an X i n e a c h s p a c e f o r w h ich

you q u a l i f y .
a* ( ) Yo u s t a r t e d w o r k on t i m e .

b. ( ) You landerstood how to read the blueprint.

c. ( ) You o b s e r v e d s a f e t y r u l e s .

d. ( ) You c o o p e r a t e d w i t h t e a c h e r a n d c lassm ates.

e. ( ) Yo u l e f t eq u ipm en t c l e a n and i n order.

( ) T o tal

BEST ANSWER: P la c e t h e number o f t h e b e s t an sw er

in th e p a re n th e se s.

a* ( ) The d e c i m a l e q u i v a l e n t f o r 3 / 8 ” i s : (1)

.3 5 0 . (2) . 250. (3) .3 7 5 . (4) .3 1 2 5 .

b. ( ) A ta p e r tu rn in g a tt a c h m e n t i s m ounted:

(1) in a to o l h o ld er. (2) i n a ch u ck . (3)

on t h e b a ck o f t h e l a t h e . ( Ip) o n t h e h e a d -

sto ck .
 47

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 kB
CHAPTER 1 0 , SCRIBER
HOW TO CONSTRUCT A TOOL TO HE USED TO MARK OR LAY OUT WORK

More a c c u r a t e l a y o u t w o r k w i l l b e l e s s d iffic u lt if

you have t h e p r o p e r t o o l w i t h w hich t o do t h e job. T h is to o l

is a scrib er, and i t c a n be u s e d i n c l a s s e s o th e r than

m a c h i n e s h o p a s w e l l a s i n t h e home w o r k s h o p . Many o f y o u

h a v e f a t h e r s a n d b r o t h e r s who w i l l a p p r e c i a t e a good s c r i b e r .

Why n o t m ake o n e o r m o r e f o r g i f t s ? It is d i f f i c u l t f o r the

s c h o o l to k e ep an a d e q u a te s u p p ly o f s e r i b e r s in the to o l

room . If y o u do n o t n e e d a s c r i b e r , th is is an e x c e l l e n t

o p p o r t u n i t y f o r you t o do t h e s c h o o l a s e r v i c e b y m a k i n g

a s c r i b e r f o r t h e t o o l room * Yo u w i l l g a i n v a l u a b l e s k i l l s ,

as th e re are o p eratio n s not re q u ire d in o th er p r o je c ts .

A. DIRECTIONS; The f o l l o w i n g s te p s w i l l g u id e you i n con­

stru c tin g a scrib er* (See b l u e p r i n t o f s c r i b e r # 1 0 .}

1. How t o make t h e b o d y .

a. Cut o f f a p ie c e of 5/16" d iam e te r x 3 l / 8 M long

c o l d r o l l e d s t e e l i n t h e p o w e r h a c k saw*

b. P lace the sto ck i n a u n iv e rs a l th re e jaw chuck

and fa c e t h e ends so m a t e r i a l m e a su re s 3 l / l 6 w

lo n g .

c. A d j u s t s t o c k so one end e x t e n d s 2 W o u t o f t h e

chuck and c e n t e r d r i l l e n d t o m e a s u r e 5/ 3 2 ”

a c r o s s th e c e n t e r hole*
 ij.9
d. Support th e end w ith, t a i l s t o c k c e n t e r an d k n u r l

s e c tio n 1 l/lf ” lo n g .

e. T u r n t a p e r on t h e e n d a c c o r d i n g to s p e c i f i c a ­

tio n s on b l u e p r i n t .

f. D r i l l N o . 2 9 x 5 / 8 M d e e p a n d t a p 8 - 3 2 N. G.

g. R everse 3toek i n th e chuck and m achine th e o th er

end i n th e same o r d e r .

h. T u r n 9 / l 6 ,f c e n t e r s e c t i o n t o 7 / 3 2 ” d i a m e t e r .

2. How t o m ak e t h e p o i n t s .

a. C u t o f f No. 2 1 d r i l l rod3 l / 8 ” long w ith hand

hacksaw .

b. P lace in u n iv e r s a l th re e ja w c h u c k w i t h 1 1/ i f ”

e x ten d in g , and c u t ta p e r as p e r b lu ep rin t.

c* F in is h w ith sm ooth f i l e and p o lis h w ith fin e

1
a b ra s iv e c lo th and o i l .

d. C u t 8 - 3 2 N . C. th re a d w ith b u tto n die and s t o c k .

e. T r a n s f e r work t o the f o r g e , h e a t ta p e re d end of

one p o i n t t o a c h e r r y red, and bend 90° as p e r

b lu ep rin t.

f. H eat bo th p o in ts to c h e r r y r e d and quench i n o i l

or w ater.
g. P o lish p o in ts w ith fin e a b r a s i v e e l o t h and o i l .
h. Temper p o i n t s b y d r a w in g t o a d a r k s t r a w c o l o r .
3* How t o a s s e m b l e the s c r i b e r .
a. T ransfer p arts t o work b e n c h .
b. Screw the points into the body and tighten.
 5o
B« ACTIVITY ASSIGNMENT; L a b o r a t o r y work t o b e a c c o m p l i s h e d ,

1* C o n stru ct a s c r ib e r according to d irec tio n s*

2. D e s ig n a s c r i b e r and l i s t th e o p eratio n s n ecessary

f o r m aking t h e scrib er.

C. EVALUATION: M ethods t h a t may b e u s e d t o c h e c k y o u r p r o ­

gress and u n d e r s ta n d in g o f t h e to o ls you have i n the sh o p .

1. PRECISION DEVICES: U se o f e x a c t i n s t r u m e n t s t o c h e c k

w o rk *

a. Check d i m e n s i o n s w i t h s t e e l rule*

b* Check t h r e a d s w i t h t h r e a d gage*

2* IDENTIFICATION; P l a c e name o f t o o l i n s p a c e p r o v i d e d *

d.

3* MATCHING: P lace th e number o f the a r t i c l e in the

paren th eses before th e sta te m e n t t o w hich i t b elo n g s,

a. ( ) Remove l i v e cen ter. 1 . S oluble c u ttin g o i l .

b* ( ) F i l e work i n l a t h e . 2 . Knockout b a r .

c. () Cut a ta p e r* 3 . Tap a n d d i e .

d* () Cut t h r e a d s . 1}.. Compound r e s t *

e* ( ) Hone e d g e o f t o o l s * 5* D r i f t .

6. M ill f i l e .

7» O i l s t o n e *
 51

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 52

PART I I . THE AMATEUR

PROJECTS FOR SECOND SEMESTER STUDENTS

T h e s e p r o j e c t s w e r e s e l e c t e d f o r y o u s t u d e n t s who

w is h t o e x p l o r e m ore t h o r o u g h l y t h e p o s s i b i l i t i e s offered

you i n the i n d u s t r i a l a r t s m achine shop c l a s s . They a l s o

g iv e you a w id e r ra n g e o f e x p e r ie n c e s i n th e u se o f hand

to o ls and th e o p e r a t i o n o f t h e m a c h in e s i n t h e shop*

The p r o j e c t s i n t h i s group a re o f w id e r r a n g e , and

some o f t h e m m ay b e u s e d i n t h e home* The t o o l s m ad e t h i s

s e m e s te r , com bined w i t h th e t o o l s m ad e t h e f i r s t s e m e s t e r ,

w i l l make a n e x c e l l e n t home to o l k it*

T ools i n t h i s g ro u p a re su ch t h a t t h e y c a n be u se d i n

t h e s c h o o l t o o l rooms o f t h e h i g h s c h o o l a n d o t h e r s c h o o l s I n

the d i s t r i c t * I f y o u w i s h t o m ak e t o o l s f o r t h e sch ool, you

w i l l s a v e m oney t h a t may be u s e d t o b u y o t h e r e q u i p m e n t .
 53
CHAPTER 1 1 . SCREW DRIVER
HOW TO CONSTRUCT A TOOL TO TURN SCREWS

No c l e a n j e a n s , flie s in th e house, and a le a k y

fa u c e t in the k itc h e n s in k — s i t u a t i o n s 'lik e these c a n be

av o id ed i f you have nim ble f i n g e r s and a sm all k i t o f t o o l s .

Of c o u r s e , th ere s h o u l d be a s c re w d r i v e r i n t h e k i t in

o r d e r to r e p a i r th e w ashing m ach in e, sw ing t h e s c r e e n d o o r,

and sto p th e le a k i n th e k itc h e n sink. J u s t t h i n k o f how

m u ch o f t h a t " f o l d in g s t u f f " you c an save tow ard som ething

rea lly im p o rtan t, such as a s e t of h o t sp a rk p lu g s. Now I s

th e tim e t o make t h e screw d r i v e r i n o r d e r to have i t t o do

th is r e p a i r w ork. Not o n ly w i l l you be a p p r e c i a t e d f o r

b e i n g e q u ip p e d t o a s s i s t a ro u n d t h e home, b u t you w i l l g a i n

new e x p e r i e n c e s i n o p e r a t i n g t h e l a t h e . In te rn a l boring,

ream ing, and m ach in in g to a p r e s s f i t a r e m achine o p e r a t i o n s

t h a t a r e new t o y o u .

A. DIRECTIONS: S u ggestions t h a t w i l l e n a b le you to c o n s t r u c t

a screw d r i v e r . (See b l u e p r i n t o f screw d r i v e r # 1 1 . )

1. How t o make t h e c a p .

a. U se c o l d r o l l e d steel 7 / 8 " d i a m e t e r x If1 /If.”l o n g .

b. Cut m a t e r i a l t o size i n p o w e r h a c k sa w .

c. P l a c e work i n th e th ree jaw u n i v e r s a l c h u c k on

th e l a t h e w ith 2" e x te n d in g .
 SK

d. Pace th e end.

e. C e n te r end w ith c e n t e r d r i l l h e l d i n d r i l l chuck

m ounted i n t h e t a i l s t o c k c e n t e r .

f. D r ill 5 /8 M hole in end as p e r b l u e p r i n t .

g. Turn s e c t i o n to be th r e a d e d to l l / l 6 n d ia m e te r x

3 / 8 i n len g th .

h. P lace k n u rlin g to o l in to o l p o s t and k n u rl la rg e

d iam eter se c tio n .

i. T u r n s e c t i o n t o b e t h r e a d e d t o l l / l 6 tt d i a m e t e r x

3 /8 ".

j. Cut r e c e s s f o r t h r e a d i n g . Use a p a r t i n g t o o l f o r

th is o p e ra tio n .

k. S e t up l a t h e f o r th r e a d in g and c u t th re a d s as

per b lu ep rin t.

2. How t o m ak e t h e h a n d l e .

a. Use s t o c k l e f t fro m t h e c a p .

b. Pace th e end.

c. C en ter d r i l l th e end w ith c e n te r d r i l l h e ld in

d rill c h u c k m ounted i n t a i l s t o c k sp in d le. Use

nE n c e n t e r d r i l l w ith 1 /8 ” p i l o t d rill.

d. A d j u s t w o rk i n c h u c k so d r i l l e d end e x te n d s

2 3A ".
e. Remove t h e d r i l l chuck from th e t a i l s t o c k sp in d le

and p la c e h a rd en ed c e n te r i n th e s p in d le .
f. A djust t a i l s t o c k so i t supports d r i l l e d end o f

w ork.

g. T urn s t o c k t o siz e and k n u rl a s p e r b l u e p r i n t .

h. D r ill 5 /8 ” h o le in end and t a p I l / l 6 ” - l 6 N .F.

i. Screw cap i n t o h a n d le .

j. Turn r a d i u s on e n d o f cap a s p e r b l u e p r i n t .

k. R e v e rs e t h e work i n t h e ch u ck an d l e a v e 1 1 / 2 ”

ex ten d in g . Use s o f t b r a s s t o p r o t e c t k n u r l e d

sectio n .

1. Face to p ro p e r le n g th .

m. S e t compound r e s t a t 9 8 ° t o t h e r i g h t , read in g

from th e h e a d s to c k s id e .

n. T urn t a p e r a s p e r b l u e p r i n t .

o. C en ter end w ith c e n t e r d r i l l h e ld in d r i l l chuck

m ounted i n t h e t a i l s t o c k sp in d le.

p. D r i l l 17/61/' h o le f o r b la d e . D rill 3 /l6 " p ilo t

h o le f i r s t .

How t o m ake t h e b l a d e and assem ble i n h a n d le .

a. U s e l / l f ” x If 1 / 2 ” o ctag o n t o o l steel.

b. Cut m a t e r i a l w i t h h a n d h a c k sa w .

c. P re ss s to c k in to h an d le.

d. Lay out and d r i l l 1 /8 ” hole f o r i n s e r t i n g p in .

e. C o u n t e r s i n k s l i g h t l y on b o t h s i d e s .

f. T r a n s f e r w ork t o t h e f o r g e and f o r g e b l a d e as

per b lu ep rin t.
 56
g. Draw f i l e o r g r i n d to a sm ooth f i n i s h .

h. H arden end o f b l a d e — draw te m p e r t o straw c o lo r.

i. I n s e r t l / 8 ,f p i n a n d r i v e t b o t h e n d s .

j. P ile ends of p in f lu s h to su rfa c e o f the h an d le,

k. P o lish e n tire screw d r i v e r w ith f in e a b r a s iv e

clo th .

B. ACTIVITY ASSIGNMENT: Work t o b e d o n e i n t h e s h o p .

1. Make a s c r e w d r i v e r a s d i r e c t e d .

2. Make a s c r e w d r i v e r , u sin g hexagon m a te r ia l f o r th e

h an d le; om it th e k n u r l i n g o p e r a t i o n .

C. EVALUATION: T ech n iq u es u se d to e v a l u a t e y o u r p e rfo rm a n c e .

1. PRECISION DEVICES: Use o f e x a c t i n s t r u m e n t s t o check

w ork.

a. Check a n g le of ta p e r w ith a p ro tra c to r.

b. Check t h r e a d s p e r i n c h w i t h a t h r e a d g ag e.

c. Use m i c r o m e t e r t o c h e c k o u t s i d e d iam eters.

d. U se s t e e l r u l e t o c h e c k f o r c o r r e c t l e n g t h .

2. TRUE-FALSE: P lace an X in c o r r e c t space f o r answ er.

T P
a. ( )( ) C u ttin g o i l s h o u ld be u s e d to c o o l and

lu b ric ate the d r i l l when d r i l l i n g a h o l e

in steel.
 57
b. ( )( ) You s h o u l d u s e t o o l s t e e l t o make t h e

blade of the screw d r i v e r , because i t

c o n t a i n s p r o p e r t i e s t h a t make i t p o s s i ­

ble to harden th e b lad e.

 NOTE: H PBD E N -TE M PE R
TO E >T R P W C O L O R .

D £ m /E D m w /A /Q
SCREW G G /M E &
I SHOP JOS A'-° Jf
SCPIE- £U LL J EktOEPP/MTfs'Z l i
 59
CHAPTER 1 2 . DIESTOCK
HOW TO MAKE A HOLDER FOR DIES USED
FOR CUTTING EXTERNAL THREADS

T h r e a d c u t t i n g w i l l b e m ad e e a s y i f y o u h a v e t h e

p ro p er to o ls f o r th e jo b . An a d j u s t a b l e round s p l i t d i e may

be p u r c h a s e d f o r a s m a l l f e e a n d y o u c a n make t h e d iesto ck

i n t h e m achine s h o p . You w i l l t h e n b e p r e p a r e d t o c u t e x ­

tern al th read s needed f o r r e p a ir s a r o u n d t h e home o r o n

p a r t s f o r y o u r c a r or m otor s c o o t e r . If y o u do n o t n e e d a

d i e s t o c k , m ake t h i s p r a c t i c a l to o l fo r your fa th e r or a

f r i e n d t h a t makes a h o b b y o f m aking r e p a i r s a r o u n d th e home.

You w i l l g a i n e x p e r i e n c e s in perfo rm in g the fo llo w in g

o p eratio n s on t h e l a t h e : stra ig h t tu rn in g , ta p e r tu rn in g ,

k n u rlin g , th read c u ttin g , d rillin g , and b o r in g . T he t y p e

o f jo b you do w i l l depend upon c a r e f u l p la n n in g and a c c u r a te

la y o u t w ork.

A. DIRECTIONS: P r o c e d u r e f o r m aking a d i e s t o c k . (See b l u e ­

p r in t of d iesto ck # 1 2 .)

1. How t o m a k e t h e h a n d l e , p a r t n o . 1 , 2 r e q u i r e d .

a. Cut c o ld r o l l e d s t e e l 9 / l 6 ” d iam eter x 3 3 /V 1

lo n g .

b. P lace i n a u n iv e rs a l th re e jaw c h u c k , fac e and

c en ter d r i l l .

c* M ount s t o c k b e t w e e n c e n t e r s ; d riv e w ith la th e dog.

 6o
d* Turn e n t i r e le n g th to l/2 " diam eter.

e. K n u rl and c h am fer 1 l / 2 " sectio n .

f. Turn stock end for end between centers; place

soft brass around knurled section to protect

knurl.

g. Turn t a p e r s e c t i o n .

( 1 ) Set taper attachment to cut taper 1 1 / 2 "

per ft.; set cutting tool on center.

( 2 ) Rough turn taper.

( 3 ) Finish turn taper.

h. Turn 3 / 3 2 " radius, using 3/32** forming tool.

i. Turn s e c t i o n t o be t h r e a d e d 5 / l 6 M d i a m e te r x

17/32*' l o n g . Turn .0 0 5 u n d e r s i z e f o r good f i t .

j. C u t 5/ l 6 “ 2lj. h . F . th read s.

k. C u t 1/ 1 6 ** r e c e s s t o d e p t h o f t h e th read ; th is

s h o u l d l e a v e t h e s h o u l d e r l / 8 " wide*

1. P o l i s h m achine s u r f a c e s w i t h f i n e ab rasiv e c lo th

and o i l .

m. P lace p a r t i n chuck w ith th re a d e d p a r t ex te n d in g ;

face th read ed p a rt to c o rre c t len g th .

2. How to make the body, part no. 2 .

a* C u t m a t e r i a l 1 c) / l 6 u d i a m e t e r x l / 2 M w i d e *

b* P lace m a te ria l in th re e jaw u n i v e r s a l c h u c k an d

face th e sides* S to c k s h o u ld th e n m easure 7 / l 6 M

wide*
D r i l l and bore as p e r b l u e p r i n t .

(1) C e n te r w ith c e n t e r d r i l l and d r i l l 3 /8 ” h o le.

( 2 ) D r i l l w i t h 2 7 / 6 1 j.” d r i l l a n d r e a m w i t h 7 / 8 ”

ream er.

(3) P lace b o rin g b a r i n to o l h o ld e r and b o re 1 ”

x 3 /8 ” deep.

P o lish w ith fin e a b ra siv e c lo th and o i l .

T r a n s f e r work t o work b e n c h .

D r i l l and ta p h o le s .

( 1 ) U se c e n t e r h e a d a n d s c r i b e r t o s c r i b e two

cen ter lin e s 90° a p a rt.

( 2 ) M a rk h o l e s to be d r i l l e d w ith c e n te r punch.

(3) P la c e p a rt in d r i l l v ise w ith c e n te rlin e

p e rp e n d ic u la r to d r i l l tab le. Get in s tr u c to r

to check your se tu p .

(i|.) D r i l l h o l e s f o r h a n d l e s w i t h s i z e ”l ” d r i l l .

(3) S p o tf a c e h o l e s w i t h l / 2 ” s p o t f a c e r .

(6) D r i l l hole f o r a l i e n screw w i t h #7 d r i l l .

(7) P la ce p a r t i n bench v i s e and t a p h o l e s to

correct size.

to assem ble th e d i e s t o c k .

Screw h a n d le s i n t o body as p e r b l u e p r i n t .

O b t a i n l / l j ~ 2 Q N. P . a l i e n sc re w fro m t o o l room ;

screw i t in to th read ed h o le , u sin g a l i e n w rench.

 62
B. ACTIVITY ASSIGNMENT; P ro jects to in c re a se your s k i l ls

in o p e ra tin g the l a t h e ,

1* Make a d i e s t o c k a s d i r e c t e d *

2. R ep air broken d ie s to c k s i n t h e t o o l r o o m o r home

workshop*

3* Check d e s i g n s of d iesto ck s in to o l catalo g s; make a

d iesto c k o f d i f f e r e n t design*

C* EVALUATION: M e t h o d s t h a t m ay b e u t i l i z e d to check your

know ledge and s k i l l s *

1* P laee a d ie in th e d ie s to c k and c u t th re a d s on a

piece of scrap stock*

2* TRUE-FALSE: P lace an X in c o r r e c t s p a c e f o r answer*

T F
a* ( )( ) You may u s e th e compound r e s t o f t a p e r

a t t a c h m e n t t o c u t a t a p e r tw o i n c h e s

p e r foot*

b* ( )( ) You s h o u l d l e a v e a t l e a s t *015 m a t e r i a l

t o b e r e m o v e d b y t h e r e a m e r when r e a m i n g

a 7/8" h o le .

c* ( )( ) Y ou s h o u l d u s e a d i e in preference to

the la th e f o r c u ttin g t h e 5 / l 6 w- N. F .

t h r e a d u s e d on t h e d i e s t o c k h a n d l e .

3. IDENTIFICATION: P l a c e t h e name o f t h e t o o l b e s i d e

the l e t t e r th a t corresponds to th e l e t t e r on t h e t o o l *
 MMI)MVWVA!

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 64

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 65
CHAPTER 1 3 . " T 11 TAP WRENCH
HOW TO CONSTRUCT A HOLDING DEVICE FOR
TAPS USED FOR CUTTING INTERNAL THREADS

Now t h a t y o u a r e e q u i p p e d t o c u t e x t e r n a l t h r e a d s ,

you sh o u ld p r e p a r e f o r c u t t i n g in te rn a l th read s. Many o f

th e i n t e r n a l th r e a d s a re u s u a l l y c u t w ith a t a p w hich r e ­

q u ires some d e v i c e f o r h o l d i n g a n d t u r n i n g i t . The MT n t a p

w rench w i l l do t h e job and i s e s p e c i a l l y handy f o r w orking

in clo se p la c e s such as you a re re q u ire d t o w ork i n when

o v erh au lin g c a r o r o th e r type e n g in es.

Th e s u c c e s s f u l c o m p l e t i o n o f t h i s m u l t i - p u r p o s e to ol

is, in i ts e l f , ample r e w a r d f o r t h e e f f o r t y o u p u t i n t o its

m aking. I t w i l l p r o v i d e y o u w i t h t h e o p p o r t u n i t y t o become

more p r o f i c i e n t in th e use o f shop t o o l s and equipm ent, and

may b e u s e d f o r t u r n i n g h a n d r e a m e r s , tap e x tr a c to r s , and

easy o u ts. You may m ake t h i s v a lu a b le w rench i n sh o rt order,

j u s t be w o rk in g a few h o u rs and f o l l o w i n g some s u g g e s t i o n s

l i s t e d below .

A. DIRECTIONS: S u g g e s tio n s t o g u id e you in c o n s t r u c t i n g

th e ta p w rench. (See b l u e p r i n t o f t a p w rench # 1 3 ♦ )

1. How t o make t h e p i n , p a r t no. 1.

a. C u t . off a piece of 5/l6!t drill rod 6 ” long.

b. P lace in th re e jaw u n i v e r s a l c h u c k on t h e l a t h e ;

fac e th e ends and b re a k c o rn e rs w ith a m ill f i l e .

K n u r l l l / l 6 ” s e c t i o n , u s i n g medium k n u r l ,

t o make t h e b o d y , p a r t n o . 2.

Cut s t o c k ; u s e t o o l s t e e l 7 / 8 M d i a m e t e r x If.”

long.

P e r f o r m t h e f o l l o w i n g o p e r a t i o n s on t h e l a t h e :

(1.) P l a c e sto c k in th ree jaw u n i v e r s a l c h u c k ,

fac e and c e n te r d r i l l b o th ends.

( 2 ) M ou n t b e t w e e n c e n t e r s a n d d r i v e w i t h d o g .

(3) Turn p a r t to size; se c tio n to be t h r e a d e d

sh o u ld be tu r n e d .010 u n d e r s i z e f o r good f i t .

(!{.) S e t l a t h e f o r t h r e a d in g and c u t th r e a d s .

(5) S e t c o m p o un d r e s t o n 1 5 ° a n d t u r n t a p e r .

(6) P lace in th ree jaw c h u c k a nd t u r n r a d i u s on

h a n d le end.

(7) T u r n e n d f o r e n d i n c h u c k a n d d r i l l 5 / l 6 ,f

hole in ta p e re d end.

(8) F ile and p o l i s h a l l over.

T r a n s f e r work t o d r ill press.

D r i l l and ream 5 / l 6 ” h o le i n h a n d le end.

T r a n s f e r w ork t o m i l l i n g m a c h in e ; in stall in

th ree jaw c h u c k o f d i v i d i n g h e a d w i t h t a p e r end

o u t.

(1) M o un t l / l 6 ” s l i t t i n g sa w o n t h e a r b o r .

(2) A l i g n c e n t e r o f saw w i t h c e n t e r l i n e o f w o rk

a n d sa w l / - l 6 n s l o t s as per b lu ep rin t.
 (3 ) T urn h a n d le on i n d e x h e a d t e n t u r n s f o r e a c h

slo t; ifO t u r n s a r e r e q u i r e d to rev o lv e the

work one c o m p le te r e v o l u t i o n .

(if) P i l e o f f a l l b u r r s .

f. T r a n s f e r w ork t o the fo rg e ; h a r d e n and draw tem ­

per jaw s 1" on t h e e n d .

3. How t o make t h e n u t , p a r t no. 3*

a. Cut s t o c k ; u s e t o o l s t e e l 1" d ia m e te r x 1 7 /8 u

long.

b. P e r f o r m t h e f o l l o w i n g o p e r a t i o n s on t h e lath e:

(1) P lace in th re e jaw u n i v e r s a l c h u c k , f a c e and

cen ter d r i l l one end.

(2) D r i l l 1 3 /3 2 " h o le th r o u g h s to c k .

(3) D r i l l 5 /8 " hole 1" deep.

(if) P l a c e b o r i n g b a r i n t o o l p o s t a n d b o r e l l / l 6 "

d ia m e te r and 1" deep.

(5) S et l a t h e f o r th r e a d in g and c u t t h r e a d s .

(6) T u rn work end f o r e n d a n d b o r e i n s i d e tap er.

Compound r e s t s h o u ld be s e t a t 15°
(7) Thread a s h o r t p ie c e o f s t e e l f o r an a d a p te r ,

and sc rew n u t on a d a p t e r .

( 8 ) M ount a d a p t e r i n c h u c k a n d t u r n n u t t o size.

(9) K nurl s e c t i o n 1" lo n g ; u s e m edium k n u r l .

(10) S e t compound r e s t a t 15° a n g le a n d t u r n t a p e r .

(11) F i l e and p o l is h .
 !{.. How t o a s s e m b l e t h e t a p w r e n c h .

a. P re ss p in i n to j?/l6n ho le in body; u se a rb o r

press i f necessary.

b. Screw n u t on t a p e r e d end.

B. ACTIVITY ASSIGNMENT: Work t o d o t o h e l p y o u m ake y o u r

own t o o l s sa tisfa c to rily .

1. Make a ,fT” t a p w r e n c h as d ir e c te d .

2. Check s e v e r a l d e s i g n s of tap w renches andw r ite

d i r e c t i o n s f o r m akingth e d e s i g n b e s t su ite d to your

needs.

C. EVALUATION; S a m p le s o f c h e c k - u p s t h a t may b e a p p l i e d i n

e v a l u a t i n g y o u r ta p w rench and t e c h n i c a l k n o w le d g e .

1. PRECISION DEVICES: Use o f e x a c t i n s t r u m e n t s t o c h e c k

work a c c o m p lis h e d .

a. Check a l l dim ensions w ith s t e e l r u le and c a l ip e r s .

b. Check t a p e r w i t h p r o t r a c t o r .

c. Check t h r e a d s w i t h t h r e a d g a g e .

d. Check r a d i u s w i t h r a d i u s g a g e .

2. TRUE-FALSE: P la c e an X i n c o r r e c t space f o r answ er.

T F
a. ( )( ) You s h o u l d s e t t h e b o r i n g t o o l a l i t t l e

above th e cen ter lin e o f t h e work t o be

bored.
b. ( )( ) You s h o u l d m e a s u r e t h e p i t c h o f a screw

th re a d w ith a m icrom eter c a l i p e r .

c. ( )( } You s h o u l d s e t t h e c o m p o u n d r e s t a t a n

a n g le o f 29° f o r c u t t i n g A m erican

N a tio n a l S tan d ard T hreads.

BEST ANSWER: P la c e th e num ber o f th e b e s t answ er in

paren th eses.

a. ( ) To m e a s u r e a n g l e s a n d t a p e r s y o u should use:

(1) an a n g le b lo c k . (2) a snap gage.

(3) a micrometer. (Ip) a protractor.

b. ( ) The p r o p e r l u b r i c a n t t o u s e when c u ttin g

th read s is : (1) lu b ric atin g o il.

(2) k e ro s e n e . (3) lard o il. (ij.) w h i t e l e a d .

 70

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 71
CHAPTER I k * COMBINATION CENTER PUNCH
HOW TO CONSTRUCT A TOOL FOR MAKING HOLES TO BE DRILLED
AND FOR TOOLING METAL

T h is m in ia tu r e p i l e d riv e r serves th e purpose of a

c e n t e r p u n c h a n d may a l s o h e u s e d f o r t o o l i n g a r t m e t a l o r

le a th e r. I t w i l l be h a n d y i n any s h o p . F r ie n d s t h a t do

m etal to o lin g and le a th e r to o lin g w i l l flo o d you w ith re q u e s ts

t o make t h i s p u n c h f o r t h e m . Several of th ese to o ls can be

used in th e s c h o o l t o o l room . V aluable e x p e rie n c e in k n u rl­

in g , tap er tu rn in g , ream ing, and t h r e a d in g w i l l be g a in e d i n

m aking t h i s to o l.

A. DIRECTIONSi K e y p o i n t s t o g u i d e y o u i n m a k i n g t h e com­

b in a tio n c e n te r punch. (See b l u e p r i n t o f c o m b i n a t i o n

c e n t e r p u n c h # l l 4-. )

1. How t o make the s l i d i n g head.

a. Cut the sto ck to s iz e .

(1) Use c o l d r o l l e d s t e e l 1 l / 2 !td i a m e t e r .

(2) C u t o f f 2 l / l 6 ”l o n g i n power saw.

b. Face ends in th re e jaw c h u c k .

( 1 ) F ace one e n d s q u a r e .

(2) R everse s to c k i n the ch u ck .

(3) Face th e o t h e r end o f f u n t i l sto c k m easures

2'* l o n g .

c. Mount s t o c k b e tw e e n c e n t e r s .
 (1) C e n te r d r i l l one e n d ; d rill through w ith a

2 3 / 6I4." d r i l l .
( 2 ) Ream h o l e to .375# u sin g slow s p e e d and a p p l y ­

ing c u ttin g o il.

(3) T r a n s f e r to a r b o r p r e s s and p r e s s 3 / 8 ”

m andrel i n to the ream ed h o l e .

(I4.) P l a c e l a t h e d o g on o n e e n d a n d m o u n t t h e

m an d rel betw een c e n t e r s on t h e l a t h e .

d. M achine t h e s l i d i n g h e a d t o s i z e .

( 1 ) T u r n e n t i r e l e n g t h down t o 1 j / l 6 n d i a m e t e r .

(2) S e t l a t h e f o r k n u r lin g and k n u r l e n t i r e

len g th . U se s l o w s p e e d a n d f l o o d w i t h

c u ttin g o il.

(3) T u rn s e c t i o n on e n d t o 3 / V d iam eter x l / 8 ”

w ide.

( I4.) S e t c o m p o u n d r e s t a t 30° an g le as p e r b lu e ­

p rin t.

(5>) C h a m f e r t h e o t h e r e n d a s p e r b l u e p r i n t .

(6 ) T r a n s f e r work to t h e a r b o r p r e s s a n d rem ove

the m an d rel.

How t o m a k e t h e b o d y .

a. Cut sto c k to len g th .

( 1 ) U se c o l d r o l l e d s t e e l 7 / 8 wd i a m e t e r .

(2 ) Cut t o 3 l / 2 ** l o n g i n pow er saw.

b. M achine body to s i z e .
(1 ) G r i p work i n t h r e e jaw u n i v e r s a l c h u c k a n d

f a c e one e n d s q u a r e ; cen ter d r i l l end.

(2) G rip m a t e r i a l i n chuck w ith 3 ” e x te n d in g ;

su p p o rt t h i s end w ith t a i l s t o c k cen ter.

(3) T urn m a t e r i a l down t o c o r r e c t s i z e .

(I}.) S e t l a t h e f o r k n u r l i n g a n d k n u r l s e c t i o n a s

per b lu ep rin t.

(5) U ndercut re m a in d e r of h a n d le to d e p th o f th e

k n u rl.

(6) S e t compound r e s t 60° to r i g h t , re a d in g from

head sto ck s id e . Turn 60° t a p e r a s p e r b lu e ­

p rin t.

(7) R everse s to c k i n th e chuck and fa c e to co r­

re c t len g th . Body s h o u l d m e a s u r e 3 ” l o n g .

D r i l l h o l e s t o b e ream ed o r t a p p e d .

(1) C e n te r end f o r d r i l l i n g and d r i l l 5 / l 6 n hole

1” deep.

( 2 ) T ap 3 / 8 - l 6 N . C . a n d c o u n t e r b o r e 3 / 8 ” x l / 8 ”

deep •

(3) R e v e rse work i n th e chuck.

(Ij.) D r i l l h o l e w i t h WCM d r i l l a n d ream .250;

c o n t i n u e t h r o u g h w i t h 5 /3 2 d r i l l to in te r s e c t

3/8 h o ie •

(5) T r a n s f e r work t o d r i l l p r e s s , d r i l l hole near

ta p e re d end, a n d t a p I / I 4. - 2 0 N.C» x l / 8 deep.

 7k
3* How t o m ak e t h e g u i d e b a r .

a. Cut m a t e r i a l to s iz e .

(1 ) Use c o l d r o l l e d s t e e l l / 2 n d i a m e t e r x 5 l / 2 w

lo n g .

( 2 ) C u t m a t e r i a l t o l e n g t h on p o w e r s a w .

b. M achine t h e g u i d e b a r to s i z e .

(1 ) G r i p work i n t h r e e jaw u n i v e r s a l c h u c k .

(2) Pace and c e n te r d r i l l b o th e n d s.

(3 ) Mount work b e tw e e n c e n t e r s .

(if) T u r n w o r k t o d i a m e t e r s p e c i f i e d o n b l u e p r i n t .

c. K nurl ^ / l G n s e c t i o n .

d. Set lath e fo r th re a d in g and c u t 3 /8 " thread

as p e r b l u e p r i n t .

e. P l a c e w ork i n th ree jaw c h u c k a n d f a c e k n u r l e d

end so b a r m e a su re s 5 M l o n g .

k» How t o m ake t h e c e n t e r p u n c h .

a. Use l / k n d r i l l r o d 2 ” l o n g .

b. Cut m a t e r i a l w i t h han d h ack saw.

c. P lace i n fo u r jaw ch u ck and c e n t e r a c c u r a t e l y .

d« S e t c o m p o u n d r e s t a t 9&° t o r i g h t and tu rn tap er

1" l o n g .

e. P l a c e work i n t h r e e jaw c h u c k a n d f a c e k n u r l e d

end so b a r m easu res 5 M l o n g .

f. P o lish w ith fin e abrasive c l o t h and o i l .

g. H arden and tem per p o in t*

 (1) T r a n s f e r t o th e f o r g e and h e a t s lo w ly to a

cherry red.

(2 ) Quench i n o il or w ater.

( 3 ) Draw temper to straw color.

(If) R e p l a c e i n l a t h e and p o l i s h .

How t o m a k e o t h e r p u n c h e s .

a. Use l / i f ,! d r i l l r o d 2 tt l o n g .

b. Cut m a t e r i a l w ith hand hack saw .

c. P ace en d s on l a t h e .

d. G rin d d e s ir e d p a t t e r n on th e end, u sin g p e d e sta l

g rin d er.

e. H arden and tem p er p u n ch .

(1) T r a n s f e r to f o r g e and h e a t to c h e r r y r e d .

(2) Quench i n o i l or w ater.

( 3 ) Draw t e m p e r t o s t r a w c o l o r .

(if) R e p l a c e i n t h e l a t h e and p o l i s h .

How t o a s s e m b l e th e to o l.

a. T ransfer a l l p a r t s t o work b e n c h .

b. P la ce punch i n ta p e r e d end o f bod y.

c. Screw l/lf M a l i e n screw i n to body to h o ld punch in

p lace.

d. P l a c e s l i d i n g h e a d on g u i d e b a r and sc re w g u id e

bar in to th e body.
 76
B* ACTIVITY ASSIGNMENT: S u g g e ste d a s s ig n m e n ts t o be done

in c la s s *

1* Make a t o o l a s d irected *

2* Make a v a r i e t y o f p u n c h e s f o r t o o l i n g a r t m etal and

leath er*

3* D em onstrate to o lin g process*

G* EVALUATION: S a m p l e s o f so m e e v a l u a t i o n t e c h n i q u e s w h i c h

m ay b e u s e d *

1* PRECISION DEVICES: Use o f e x a c t i n s t r u m e n t s to

c h e c k work*
a* Check l e n g t h of p a r t s w i t h s t e e l r u l e *
to* Check d i a m e t e r of p a r t s w i t h c a l i p e r s o rm icrom eter*
c* Check a n g le w i t h p r o t r a c t o r *
d* Check t h r e a d s w i t h t h r e a d gage*
e* Check 60° p o i n t w i t h c e n t e r g a g e .

2* RATING SCALE: Put check in a p p ro p ria te s p a c e op­

p o site each q u ality *

1-poor 2 -fair 3-good Ip -e x c 'l’ t Score

F in ish

Taper
Cham fer
K nurl
T hreads

T o leran ces
A ppearance •
T o tal
 77

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 78

CHAPTER 1 5 . PARALLEL CLAMP

HOW TO MAKE A DEVICE FOR HOLDING WORK IN POSITION

O p e r a t i n g t h e m i l l i n g m a c h in e no d o u b t a p p e a r s sim ple

to you; it looks as i f a l l you have to do i s clam p t h e work

in the v ise, t u r n on t h e p o w e r, and w atch th e c h ip s r o l l o f f .

If'y o u havet h i s o p in io n o f t h e m i l l i n g m achine and want a

good t o o l , make a p a r a l l e l clam p a n d f i n d o u t j u s t what

makes t h i s m achine t i c k .

T he p a r a l l e l elam p i s n eed ed i n y o u r l a y o u t work; it

w ill ho ld th e p a r t s e c u r e ly i n p o s i t i o n and i s e a sily ad­

ju sted . T h is clam p w i l l n o t m ar o r s c r a t c h t h e m a c h in e d s u r ­

f a c e s o f p a r t s you a re l a y i n g out. You n o t o n l y u s e t h e

m i l l i n g m achine i n m aking th e clam p, b u t you p e rf o r m several

o p eratio n s on t h e l a t h e a n d u s e m an y o f t h e common h a n d

to o ls.

A. DIRECTIONS: P o in ters t h a t may b e f o l l o w e d i n m a k i n g t h e

p a ra lle l clam p. (See b l u e p r i n t of p a ra lle l clam p # 1 5 . )

1. How t o m ake t h e jaw s, p a r t s no. 1 a n d 2.

a. C u t o f f tw o p i e c e s o f c o l d r o l l e d s t e e l 3/k-'x

s q u a r e x If. 9 / l 6 ” l o n g .

b. P lace sto ck in m ill v is e ; p l a c e p a r t 1 on t o p o f

p a r t 2 w ith b o th p a r ts ex ten d in g 1 ” out o f th e

v ise.
 79

c. P lace a 3 / V concave c u t t e r on th e m i l l i n g

m achine a r b o r and m i l l th e 3/if n r a d i u s .

d. Cut s t o c k t o co rre ct len g th , u sin g a staggered

to o th c u tte r.

e . ' Lay o u t t a p e r e d end and h o l e s t o be d r i l l e d .

(1) T r a n s f e r work to l a y o u t b e n c h .

(2) S cribe lin e s on t a p e r e d e n d s .

( 3 ) Mark h o l e s t o be d r i l l e d w i t h t h e cen ter

punch.

f. M ill ta p e r e d end.

(1) P la c e jaw s s i d e b y s i d e in th e v is e w ith

ta p e r lin e p a r a l l e l to to p sid e o f v ise jaw s.

(2) P l a c e a s l a b b i n g c u t t e r on t h e a r b o r .

(3) M ill p a r t s to scrib ed lin e .

g. D r i l l and ta p h oles.

(1) P lace jaw n o . 2 on t o p o f jaw no. 1 in p o si­

t i o n as i n a sse m b ly draw ing. Clamp i n t h e

d rill v ise.

(2) T r a n s f e r work t o d r i l l p re s s and d r i l l 3 /l6 M

h o les th ro u g h p a r t no. 2 and 1 / 8 ” i n t o p a r t

n o . 1.

(3) Remove p a r t n o . 2, form th e v i s e , and d r i l l

th e p a r ts s e p a ra te ly acco rd in g to re q u ire d

sizes.

(if.) T r a n s f e r w o r k t o b e n c h v i s e a n d t a p h o l e s
 80

according to sp e cifica tio n s on t h e b l u e p r i n t ,

h. Case h a r d e n t h e jaw s.

(1) T r a n s f e r t h e work t o th e f o r g e .

(2) H eat slow ly i n fo rg e to c h e rry re d .

(3) P la c e jaw s i n c a r b u r i z i n g m a t e r i a l .

(If) Remove j a w s a n d r e h e a t t o c h e r r y r e d .

(5) Quench i n clean w ater c o n ta in in g sm all

amount o f s u l p h u r i c acid .

2. How t o make t h e screw s, p a r t s no. 3 a n d if.

a. C u t two p i e c e s o f c o l d r o l l e d s te e l 7 /8 ” d iam eter,

p a r t no. 3 , if 3 / l 6 " lo n g , and p a r t no. if, if l / 8 M

lo n g .

b. Pace ends to le n g th and c e n te r d r i l l .

c. Mount b e t w e e n c e n t e r s a n d r o u g h t u r n l a r g e

diam eter se c tio n .

d. Rough t u r n sm all d ia m e te r s e c t i o n .

e. F in ish tu rn larg e diam eter se c tio n .

(1) C h a m f e r iff?0 x l / l 6 n a s p e r b l u e p r i n t .

(2) Turn 9 / l 6 n d ia m e te r s e c t i o n .

f. K nurl l a r g e diam eter s e c tio n .

g. R everse s to c k betw een c e n t e r s ; place soft sheet

b r a s s o v e r k n u rl to p r e v e n t m a rrin g by dog.

h. S e t l a t h e f o r t h r e a d in g and c u t th e 3 /8 -1 6 -N . C.

th read s.

i. T urn s e c t i o n on end o f p a r t no. if t o d ep th of

 81

th rea d . T h is sh o u ld f i t b l i n d h o le i n no. 1 jaw .

3. How t o make r e t a i n e r c l i p , p a rt no. 5*

a. Cut 1 / 8 ” x 3 A ” x 1 1 / 2 ” c o l d r o l l e d s t e e l .

b. Lay o u t an d d r i l l #10 h o le l / l f ” from end.

c. Lay o u t and d r i l l 7 / 1 6 ” h o l e 1 ” f r o m sa m e end.

d. Cut o f f t h r o u g h c e n t e r o f 7/ 1 6 ” h o l e .

e. G r i n d 3/ 8 ” r a d i u s as p e r b lu e p rin t.

f. M ill to c o rre c t th ick n ess.

(1) M i l l e n d w i t h r a d i u s l / l 6 ” x 1/ 2 n l o n g .

(2) T u r n p a r t o v e r a n d m i l l o t h e r e n d l / l 6 ,f x

3 /8 ” long.

ij.. How t o a s s e m b le clam p.

a. T ransfer a ll p a rts t o work b e n c h .

b. A ssem ble p a r t s in p o sitio n shown i n a s s e m b l y

draw ing.

c. (1) P la c e jaw s i n p o s i t i o n shown i n a s s e m b l y

draw ing.

(2) S lid e screw no. 3 th ro u g h h o le i n p a r t no. 1.

(3) S lid e r e ta in e r c lip in to p o sitio n .

(ij.) O b t a i n 1 0 - 3 2 s c r e w f r o m t o o l r o o m a n d f a s t e n

clip in p o sitio n .

(5) Screw p a r t no. l|_ t h r o u g h h o l e i n p a r t n o . 2;

end o f screw sh o u ld s l i d e in to b lin d hole in

p a r t no. 1.

(6 ) A d j u s t clam p jaw s t o d e s i r e d o p en in g .
B. ACTIVITY ASSIGNMENT: P r o j e c t s f o r l e a r n i n g t o s e t up

and o p e r a t e t h e m i l l i n g m achine and s h a p e r .

1. Make a p a r a l l e l clam p a s d i r e c t e d .

2. Make a p a r a l l e l clam p a c c o r d i n g t o t h e d i r e c t i o n s ,

u sin g th e shaper to cut the ta p e r in ste a d of u sin g

t h e m i l l i n g m achine.

C. EVALUATION: S a m p l e s o f some t y p e s o f c h e c k - u p s w h i c h

may b e a p p l i e d t o y o u r p r o j e c t .

1. PRECISION DEVICES: U se o f e x a c t i n s t r u m e n t s to check

work.

a. Check t h r e a d s w i t h t h r e a d g a g e .

b. Check o u t s i d e dim ensions w ith m icrom eter c a l i p e r s .

c. Check a n g l e w i t h p r o t r a c t o r .

d. Check r a d i u s w i t h r a d i u s g a g e.

2. RATING SCALE': P lace an X in each sp a ce f o r w hich

you q u a li f y .

a. ) You r e m o v e d c h i p s f r o m t h e m a c h i n e w i t h a

brush.

b. ) You made s u r e t h a t e v e r y t h i n g would r u n c l e a r

before s t a r t i n g m ach in e.

c. ) You d i d n o t l e a v e t h e m a c h i n e w h i l e i t was

run n in g .

d. ) You u s e d s u f f i c i e n t c o o l a n t s on t h e c u t t e r s .

e. ) You c h e c k e d w o r k p e r i o d i c a l l y .
( ) T o tal.
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 8k

PART I I I . THE PRO

PROJECTS FOR ADVANCED STUDENTS

S p e c i a l e f f o r t w a s made t o se le c t p ro jec ts t h a t w ould

be o f i n t e r e s t to y o u r group. They have b e n e f i t s f o r th o se

o f y o u who a r e in te reste d in e n la rg in g your to o l k its o r who

own a m o t o r s c o o t e r o r a c a r .

The v i s e s h o u l d b e a ’’m u s t ” f o r y o u who a r e sta rtin g

a home w o r k s h o p . I t p ro v id es ex p erien ce in o p eratin g a ll

m achines i n th e shop and r e q u i r e s c a re fu l p lan n in g . The

D r i l l V ise Job w i l l r e q u i r e a fu ll sem ester to com plete, but

i s w e ll w orth th e e f f o r t . You g a i n m an y v a l u a b l e e x p e r i e n c e s

a n d h a v e a r e a l l y w o r t h w h i l e p r o d u c t when i t is com pleted.

A flarin g t o o l and s o c k e t w rench h a n d le a r e b o th handy

to o ls if y o u do y o u r own r e p a i r w o r k on y o u r s c o o t e r o r c a r .

The p r e s s u r e pump i s a " m u s t 11 i f you a r e ’’h o p p i n g ” u p t h a t

’’r o d " o f y o u r s . It w i l l come i n h a n d y o n t h a t s to c k job i f

t h e f u e l pump i s somewhat l a z y .

You w i l l f i n d t h a t m any o f y o u r f r i e n d s w i l l b e e a g e r

to purchase these a r t i c l e s fro m you i f you w i l l do a g o o d

jo b i n m aking them .
 85

CHAPTER 1 6 . SOCKET WRENCH FLEX HANDLE

HOW TO MAKE A DEVICE FOR HOLDING AND TURNING SOCKETS

Now i s t h e t i m e t o m ak e t h a t s o c k e t w r e n c h h a n d l e y o u

have been need in g . T h is h a n d le can be u se d a s a b re a k over

ty pe, o r y o u may i n s e r t the p in in th e h o le in th e hand g rip ,

a n d y o u h a v e a ”T n h a n d l e . A ctu ally i t is a two i n one

h a n d l e w i t h a l / 2 ,r d r i v e . As t h i s d rive fits a v a rie ty of

so ck ets and attach m en ts i t is in d is p e n s a b le f o r use in r e p a i r

o r o v e r h a u l w ork. You c a n e a s i l y see what an a d v an tag e i t

w i l l be to have t h i s t o o l th e n e x t tim e you o v e rh a u l t h a t c a r

o r you work i n y o u r a u to shop c l a s s .

In a d d itio n to th e f a c t t h a t you g a in a good t o o l , you

save y o u r s e l f some '’d o u g h 1* b y m a k i n g i t i n m achine shop.

More e x p e r i e n c e w i l l b e g a i n e d i n o p e r a t i n g t h e l a t h e , d rill

press, and m i l l i n g m ach in e. W ith an u n d e r s t a n d i n g o f t h e s e

o p e ra tio n s, you a ls o receiv e a s a t i s f a c t o r y grade in your

m achine shop c l a s s .

A. DIRECTIONS: The f o l l o w i n g d i r e c t i o n s w i l l a s s i s t y o u i n

m aking t h e s o c k e t w rench f l e x h a n d le . (See b l u e p r i n t o f

f l e x h an dle # l 6 . )

1. How t o make t h e b o d y , p a r t n o . 1.

a. Cut one p i e c e of spring s t e e l 1 l / l 6 ” diam eter

x 5 5 / l 6 ” long.
 C om plete t h e f o l l o w i n g o p e r a t i o n s on t h e l a t h e :

( 1 ) Mount i n u n i v e r s a l t h r e e jaw c h u c k ; fa c e and

c e n te r d r i l l b o th ends.

( 2 ) Mount b e t w e e n c e n t e r s a n d d r i v e w i t h l a t h e

dog.

(3) Turn l a r g e d iam eter s e c tio n to 1” in d iam eter.

(Ij.) T u r n s t o c k e n d f o r e n d b e t w e e n c e n t e r s .

(5) Rough t u r n h a n d g r i p .

(6) R o ug h t u r n r e m a i n d e r o f h a n d l e .

(7) Rough t u r n 3 / 8 ” r a d i u s , two p l a c e s .

(8) F i n i s h t u r n a l l over.

(9) K nurl s e c t i o n as p e r b l u e p r i n t .

(10) C h a m f e r e n d 1 / 8 ° x Ip50 •

(11) P o l i s h w ith f i n e a b r a s i v e c l o t h an d o i l .

T r a n s f e r work t o t h e m i l l i n g m achine.

M ill f l a t s i d e s on h e a d as p e r b l u e p r i n t .

R evolve t h e work 90° a n d m i l l t h e 1 / 2 " s l o t 7/8"

lo n g .

R a is e t a b l e o f m ac h in e i n o r d e r t h a t work i s

same h e i g h t a s t h e a r b o r . Use a c u t t e r l / 2 "

w ide a n d 3 ” i n d i a m e t e r .

M ill 1 /2 " r a d i u s on th e end.

T r a n s f e r work t o d r ill press, d r i l l 3/1& " h o l e ,

a n d c o u n t e r s i n k 7/ 3 2 " x 8 2 ° .
D r i l l 1 /8 " h o le f o r s p r in g and b a l l . (purchase
 87
the sp rin g s and s t e e l b a l l s fr o m p a r t s h o u s e . )

2. How t o m ak e t h e d r i v e , p a r t n o . 2*

a* Cut a p ie c e o f t o o l s t e e l l / 2 ft x 3 / V f x 1 £ / 8 ,f.

b. P lace in v is e on t h e m i l l i n g m a c h in e and m i l l

the l / 2 " rad iu s o n one e n d .

c. M il l o p p o s i t e end so i t is l / 2 tt s q u a r e .

d. T r a n s f e r work t o d r i l l p r e s s and d r i l l l / 8 H h o le

fo r sp rin g , t h e 3/ 1 6 ” h o l e , a n d t h e d i m p l e on

the end.

3* How t o a s s e m b l e the h a n d le .

a. P lace sp rin g s and s t e e l b a l l s in h o les d r i ll e d

f o r them a n d s e t them i n p l a c e w i t h d i m p l i n g t o o l .

b. Cut a p ie c e of 3 /l8” d r i ll r o d 1l / l 6 M l o n g .

c. P lace d r iv e in s l o t in the h a n d le ; lin e up t h e

h o les and i n s e r t the 3 / l 6 ” p in .

d. Peen th e ends of th e p in to p re v e n t i t from

slip p in g out; file ends f l u s h and p o lis h .

e. P lace s p rin g and s t e e l b a l l in the h o le i n the

d riv e; use dim pling t o o l to set i t in p lace.

B. ACTIVITY ASSIGNMENT: P ro je c ts th a t w ill in c re a se your

p r o fic ie n c y in the use of the l a t h e and m il l in g m achine.

1. Make a s o c k e t w r e n c h h a n d l e a s d i r e c t e d .

2. D e s i g n a s o c k e t w r e n c h w i t h d i f f e r e n t d r i v e a n d make

it according to th ese d irec tio n s.

 3. A s s i s t one o f y o u r c l a s s m a t e s i n m aking a s o c k e t

w rench h a n d le .

C. EVALUATION; S a m p l e s o f e v a l u a t i o n i n s t r u m e n t s w h i c h may

be ap p lied in r e la tio n t o y o u r work i n the shop.

1 . TRUE-FALSE: P lace an X in th e c o rr e c t space fo r

tru e or false.

T F
a. ( )( ) It i s b e s t t o m easure w ith th e r u le on

its edge.

b. ( )( ) It i s w ise to co v er a c u t com pletely

w ith tap e .

c. ( )( ) You s h o u l d u s e a board to p r o te c t th e

ways o f t h e l a t h e when r e m o v i n g c h u c k .

2. BEST ANSWER: P la c e th e number o f th e b e s t an sw er i n

p aren th eses.

a. ( ) To make a s o c k e t w r e n c h h a n d l e y o u s h o u l d

use: (a) tem pered s t e e l . (b) c o ld r o l l e d

steel. (c) sp rin g s te e l. (d) c a s t i r o n .

b. ( ) You s h o u l d s t o r e g aso lin e in a: (a) red can.

(b) la b e le d can. (c) g lass jar. (d) open

can.

3. RATING SCALE: P la c e an X i n e ac h space f o r w hich

you q u a l i f y .

a. ( ) You u s e g o g g l e s when g r i n d i n g .
 89

b. ( ) You o b t a i n p e r m i s s i o n b e f o r e l e a v i n g the

room.

c. ( ) You do n o t a b u s e e q u i p m e n t i n t h e shop.

d. ( ) You r e a d t h e b l u e p r i n t b e f o r e a t t e m p t i n g to

do a j o b .

e. ( ) You c h e c k y o u r m a c h i n e b e f o r e t u r n i n g o n the

pow er.

f. ( ) You a s s i s t o t h e r s when t h e y n e e d a s s i s t a n c e .

( ) T o tal.
 90

D e ta il D r a w in g S O C K E T WBENCH S H O P J OG H 9 / 6
SCALE r.S.D . FLExH AND LE QiUEAE/NT IVS f€
 91
CHAPTER 1 7 . nVn -BLOCK" AND CLAMP
HOW TO CONSTRUCT A TOOL FOR HOLDING ROUND STOCK
IN POSITION

H o ld in g ro u n d work t o l a y o u t o r d r i l l p resen ts a

p rob lem u n l e s s you have a V -b lo ck and clam p. W ith th e s e

to o ls you c a n s e c u r e l y h o l d c y l i n d r i c a l work f o r l o c a t i n g

and d r i l l i n g h o les. The V - b l o c k m akes i t e a s y t o clam p

c y l i n d r i c a l work i n t h e v i s e in o rd er to perform v ario u s

o p eratio n s on m a c h in e s , su c h as the m i l l i n g m ach in e, shaper,

p lan er, and g r in d e r . T h is w i l l be a v a lu a b le to o l f o r the

home w o r k s h o p t h a t w o u l d b e r a t h e r e x p e n s i v e i f you h a d to

purchase i t from a su p p ly h o u se .

Yo u h a v e a c h o i c e o f m achines to o p e ra te i n m aking the

V -block; it c a n b e m a c h in e d on e i t h e r t h e m i l l i n g m ac h in e o r

the shaper. The d i r e c t i o n s g i v e n w i l l a p p l y t o the m illin g

m ach in e•

A. DIRECTIONS: Key p o i n t s to guide you i n c o n s tr u c tin g the

V -b lo ck and clam p. ( S e e b l u e p r i n t o f ><Vr>- B l o c k , a n d C lam p

# 1 7 .)
1. How t o m ake t h e clam p, p a r t no. 1*

a. C ut m a t e r i a l . U se 5 / 8 ” x 2 3 / 8 " x 2 l / 2 n c o l d

r o lle d ste e l*

b* A p p ly l a y o u t d y e a n d l a y o u t m a t e r i a l a c c o r d i n g

t o l a y o u t d ia g r a m *
 92

P lace m a te ria l in fo u r jaw i n d e p e n d e n t chuck*

(1) C e n te r t h e h o le t o be b o re d , u sin g a c e n te r

f i n d e r m ounted i n t o o l p o st.

(2) C e n te r d r i l l and d r i l l h o l e w i t h 1 /I|_” d r i l l .

Increase size of d r ill by l / 2 w e a c h tim e and

d r i l l h o le out to 1 1 /V 1 in d iam eter.

(3) P la ce b o rin g b a r i n to o l p o s t and b o re h o le

to 1 l / 2 H in d iam eter.

d. T ransfer m aterial to d r i l l p r e s s ; d r i l l h o les

accordin g t o la y o u t.

(1) D r i l l two l / V h o le 3.

( 2 ) D r i l l tw o l / l 6 M h o l e s .

(3) D r i l l a ll 3 /l6 M h o les.

(ij.) Drill mF m drill in top of clamp.

e. Saw to shape with hand hack saw.

f. Sm ooth a l l su rfaces w ith m ill f i l e .

g* T h re a d h o l e i n to p w i t h 5 / l 6 - l 8 N .C . tap .

2. How t o m ak e t h e s c r e w , p a rt no. 2.

a. Cut o f f one p i e c e o f l / 2 ,f h e x a g o n c o l d r o l l e d

s t e e l 3 l / 2 ,r l o n g .

b. P lace sto c k in a th ree jaw u n i v e r s a l c h u c k w i t h

2 l/l\.n ex ten d in g out o f the chuck.

e. T u r n t h i s p o r t i o n down t o ^ / l 6 n d i a m e t e r x 2 W

lo n g.

d. Set lath e f o r t h r e a d i n g a n d c u t 5 / l 6 ~ l 8 N .C .
 93
e. Turn l / 8 " rad iu s on t h e e n d .

f. T u r n s t o c k e n d f o r e n d i n t h e c h u c k a n d c u t down

to c o r r e c t le n g th .

g. Form 12 M r a d i u s on t h e h e a d b y m oving c r o s s f e e d

a n d l o n g i t u d i n a l f e e d a t t h e sa m e t i m e b y h a n d .

h. T ra n sfe r to d r i l l p re s s and d r i l l 3 /l6 n in head.

3. How t o m a k e t h e p i n , p a r t n o . 3*

a* Cut 3 / l 6 M d ia m e te r c o ld r o l l e d s te e l 2H long,

b. Break c o r n e r s oh b o t h ends w ith m i l l f i l e .

I}.. How t o m a k e t h e V - b l o c k , p a r t n o . l^..

a. C u t 1 1 / 2 ” x 1 1 / 2 ’* x 2 l / l 6 ° co ld r o lle d ste el.

b. P l a c e i n f o u r jaw chuck; t r u e up and f a c e ends

to c o r r e c t -length.

c. M ill to shape.

( 1 ) Clam p i n v i s e on t h e m i l l .

( 2 ) Mount 1/l\.n s t a g g e r e d t o o t h c u t t e r on th e

a r b o r a n d m i l l 1/ l ± n s l o t s .

(3) P la ce l / 8 w s l i t t i n g saw on t h e a r b o r an d

m ill l / 8 H s lo ts .

( ip) P l a c e i|_5° a n g l e c u t t e r on t h e a r b o r a n d m i l l
t h e 9 0 ° V 1s .

d. T r a n s f e r w ork t o s u r f a c e g r i n d e r and ro u g h grin d .

e. T r a n s f e r work t o f u r n a c e and e a s e h a r d e n .

(1) P la c e cru cib le co n tain in g e a rb u riz in g

m aterial over fu rn ace and m e lt.

 9k-
(2) D ry V -b lo ck o v e r fla m e .

(3) T ie a w ir e a r o u n d V - b l o c k and subm erge i n

m o lte n s o l u t i o n f o r 30 m i n u t e s .

(k-) Remove a n d q u e n c h i n w a t e r ,

g. T ra n sfe r to s u rfa c e g r i n d e r and f i n i s h g r in d ;

you s h o u ld g r i n d o n ly .0 0 3 d e e p .

5. How t o a s s e m b l e V - b l o c k a n d c l a m p .

a. D rive 3 / l 6 H p in i n to h o le i n head o f t h e screw *

b. Turn screw i n t o the th read ed hole i n th e clam p.

c. S lid e fin g e rs o f c l a m p i n t o l . ^ 1* s l o t s in sid es

of th e V -block.

B. ACTIVITY ASSIGNMENT: P r o j e c t s to p e r f e c t your a b i l i t y to

operate t h e m achine e f f i c i e n t l y .

1. Make a V - b l o c k a s d i r e c t e d .

2. Make a V - b l o c k , u sing the sh a p e r in s te a d of th e

m i l l i n g m ach in e.

C. EVALUATION: S a m p l e s o f some e v a l u a t i o n t e c h n i q u e s w h i c h

may b e u s e d t o check y o u r know ledge and p e r f o r m a n c e .

1. C lam p a p i e c e of s t o c k i n t h e V -b lo c k and d r i l l a

hole in the sto c k .

2. TRUE-FALSE: P lace an X i n c o r r e c t space f o r tru e or

false.
 T P
a. ( )( ) You should be familiar with different

types of cutters if you are operating

the mill•

b. ( )( ) The spindle arbor is used for holding

different types of milling cutters,

e* ( )( ) You should use the plain vise for light

milling operations.

PRECISION DEVICES: Use of exact instruments to check

work*

a* Check dimensions with steel rule,

b* Check radii with radius gage.

c. Check threads with thread gage,

d* Check angles with protractor*

 96

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 97
CHAPTER 1 8 . GEAR PULLER
HOW TO FABRICATE A DEVICE FOR REMOVING GEARS AND PULLEYS

G ears an d p u l l e y s t h a t a r e s t u c k on s h a f t s s l i d e off

w ith e ase i f you have a g e a r p u l l e r t o a p p ly the p r e s s u r e

needed. T h is t o o l w i l l be e s p e c i a l l y h a n d y i f you r e p a i r

th e w a sh in g m achine o r o v e r h a u l t h a t m o to r s c o o t e r p e r i o d i ­

c ally . T h e j o b c a n b e d o n e m uch m o r e e a s i l y a n d i n l e s s

tim e th a n i f you r e l y on' i m p r o p e r t o o l s a n d m a k e s h i f t d e ­

vices. You b a c k y a r d m e c h a n i c s w i l l a l s o h a v e a u s e f o r t h i s

to o l.

You i n c r e a s e your s k i l l s by o p e ra tin g the m illin g

m a c h in e a n d g a i n m ore e x p e r i e n c e i n t h r e a d c u t t i n g and t a p e r

t u r n i n g on t h e l a t h e . A ccu rate la y o u t i s im p o rta n t in the

proper c o n stru ctio n of th is p ro je c t.

A. DIRECTIONS: Procedure f o r f a b r ic a tin g a g ear p u lle r .

(See b l u e p r i n t o f g e a r p u l l e r # 1 8 .)

1. How t o m ake t h e b o d y , p a r t no. 1.

a. Cut 3/V* s q u a r e c o l d r o l l e d s t e e l if. l / 2 n l o n g .

b. P lace sto ck in v ise on m i l l i n g m achine and c u t

3 / 8 rad iu s on th e e n d s. Use l / 2 ” c o n c a v e

cu tte r.

c. Cut l / l f " x 3 / b n s l o t in each end, u s in g l / 2 n s t a g ­

ger to o th c u tte r.
 98

d. D rill and ta p h o l e s a c c o rd in g to b l u e p r i n t .

(1) T r a n s f e r work t o b e n c h , la y o u t and c e n t e r

punch h o l e s t o be d r i l l e d .

(2) D r i l l l a r g e h o le w ith 3 / l 6 n p i l o t d rill and

d rill to s i z e w i t h 2 7 / 6 1 f ,f d r i l l .

( 3 ) D r i l l t h e two 3 / l 6 n h o l e s .

(if) Tap l a r g e h o l e 1 / 2 - 13 N .C . th read s.

e. P o lish e n tire su rfa ce w ith a b ra siv e c lo th and o i l .

2. How t o make t h e screw , p a r t no. 2.

a. Cut 3 / V ’ o c t a g o n t o o l s t e e l 5 l / 8 H long.

b. P lace sto ck in th ree jaw u n i v e r s a l c h u ck ; face

and c e n t e r d r i l l b o th en d s.

c. Mount s t o c k b e t w e e n c e n t e r s i n t h e l a t h e ; drive

w ith la th e dog.

d. C ham fer one end l / 8 n x lf5°.

e. R e v e rse work en d f o r end and t u r n s e c t i o n t o be

th read ed to size. T urn .005 u n d e r s i z e to obtain

good f i t .

f . Set la th e fo r c u ttin g th re a d s and th r e a d sectio n

as per b lu e p rin t.

g. P lace screw i n th r e e jaw c h u c k w i t h t h r e a d e d e n d

e x ten d in g I " . P ro te c t th read s w ith s o ft b ra ss.

h. Pace o f f c e n te r h o le and tu r n 60° p o in t.

i. T r a n s f e r work t o d r i l l p r e s s and d r i l l 3 /8 n hole

in larg e end.
3. How t o make t h e p i n , part no. 3.

a. Cut 5 / 1 6 ” d i a m e t e r x 3 3 / V l ° n g co ld r o l l e d

ste el.

b. P lace in th ree jaw u n i v e r s a l c h u c k .

(1) R o u nd e n d s w i t h m i l l f i l e .

(2) K nurl s e c t i o n 5 /8 " lo n g f o r t i g h t f i t .

if. How t o m ake t h e a r m , p a r t n o . if; two r e q u i r e d .

a. Cut l / l f " s p r i n g s t e e l if 3 / i f n l o n g .

b. L a j out acco rd in g to b lu e p r in t.

c. Form t h e arm .

(1) C u t o u t s e c t i o n a l o n g l i n e w i t h h a c k sa w ;

le a v e enough m etal to p r e s e r v e lay o u t.

( 2 ) D raw f i l e to lay o u t lin e .

(3) G rind r a d i u s on e a c h end.

d. Lay o u t and d r i l l 3/1& " h o l e .

e. Draw f i l e and p o l i s h e n t i r e arm w i t h a b r a s i v e

clo th .

5. How t o a s s e m b l e t h e g e a r p u l l e r .

a. P re ss p in in to 3 /8 " h o le in screw ; u se a rb o r

press.

b. Screw p a r t no. 2 in to th e tap p e d hole in th e

body.

c. F a s t e n arm s i n m i l l e d s l o t s in the ends o f the

body.

(1) Cut two p i e c e s o f d r i l l r o d 3/1& " i n d i a m e t e r

 100

x 1 3 / l 6 ,f l o n g .

(2) L in e up h o le i n arm w i t h h o l e in th e body

and i n s e r t 3 / l 6 n p in .

(3) Peen b o th ends of p i n to p re v e n t p i n from

w orking o u t o f th e h o le .

(!}.) P i l e o ff excess p a r t of the p in w ith m ill

file .

B. ACTIVITY ASSIGNMENT; Work t o be a c c o m p lish e d i n th e shop.

1. Make a g e a r p u l l e r a s d i r e c t e d .

2. D esign a g e a r p u l l e r f o r rem oving l a r g e r g e a rs and

make a c c o r d i n g t o a b o v e d i r e c t i o n s .

C. EVALUATION: S a m p l e s o f some t y p e s o f c h e c k - u p s w h i c h

may b e a p p l i e d t o y o u r p r o j e c t .

1. PRECISION DEVICES: Use o f e x a c t in stru m en ts to check

w ork.

a. M easure a l l p a r t s w ith a s te e l ru le.

b. Check t h r e a d s w i t h a t h r e a d g a g e .

c. Check r a d i i w i t h r a d i u s g a g e .

d. Check a n g l e w i t h a p r o t r a c t o r .

2. Remove a g e a r w i t h t h e g e a r p u l l e r t o c h e c k a c t i o n .

3. TRUE-FALSE: P lace an X in c o rre c t space f o r answ er.

T P
a. ( )( ) Some m i l l i n g o p e r a tio n s can be p e rfo rm e d

on t h e l a t h e .
 101

b. ( )( ) Tapers are usually thousands per inch.

c. ( )( ) All milling cuts should be taken with

the rotation of the cutter against the

direction of the feed,

ij.. COMPLETION: Write in the long blanks ahead of the

items the answers that should be in the short token

blanks within the items.

a. __________ - The spindle is used for

holding cutters and tools* accord­

ing to the type of work being done.

b. ______________ The swivel vise is so made that it

may be turned or swiveled at any

c. You should use a good grade of

coolant when milling to prevent

 102

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 103
CHAPTER 1 9 . FLARING TOOL
HOW TO MAKE A TOOL FOR SHAPING THE ENDS OF TUBING

T he f l a r i n g t o o l i s in d isp en sab le if you a r e m aking

i n s t a l l a t i o n s u sing seam less tubing* The f i r s t r e q u i s i t e

of a sa tisfa c to ry job i s th a t th e tu b in g be f l a r e d p r o p e r l y

t o m ake a g o o d j o i n t * I t w i l l be in c o n v e n ie n t and i n e f f i c i e n t

t o make f l a r e d t y p e j o in t s w ith o u t the a s s is ta n c e of t h i s

handy to o l. You c a r b u r e t i o n ^ e x p e r t s ’* a n d r e f r i g e r a t i o n

’’t i n k e r e r s " w i l l fin d th is to o l to be i n v a l u a b l e * Not o n l y

w i l l you save tim e , b u t y o u w i l l s a v e money a s w e l l ; sp o iled

tu b in g i s r a t h e r expensive.

T h is job a f f o r d s a v a r i e t y o f o p e r a t i o n s to be p e r ­

fo rm ed on t h e d rill press, lath e, and m i l l i n g m achine*

A ccuracy and p r e c i s i o n i n th e p r o d u c tio n o f th e t o o l w i l l

a s s u r e more a c c u r a c y an d p r e c i s i o n i n jobs th a t are to be

done w i t h t h e t o o l .

A. DIRECTIONS: K ey p o i n t s t o g u i d e y o u i n m a k i n g t h e

f la r in g to o l* ( S e e b l u e p r i n t o f f l a r i n g t o o l # 1 9 *)

1. How t o m ake t h e jaw s, p a r t s nos. 1 and 2.

a. Cut m a te r ia l to size*

(1) P a r t n o . 1, 9 / l 6 M x 9 / l 6 w x & 5 / l 5 n co ld
ro lle d steel*

(2) P a r t n o . 2 , 9 / l 6 M x 9 / l 6 M x J4. 1 / 2 H c o l d
 lOii-
ro lle d steel*

b* M ill r a d i i and s l o t s on m i l l i n g m a c h in e .

(1) P lace in v ise on m i l l i n g m achine and m i l l

l/2 ra d iu s on e a c h e n d .

(2 ) R evolve p a r t s 9 0 ° and c u ^ s l o t 5 / l 6 " x l / 2 n

i n one end o f p a r t n o . 1 and i n b o t h e n d s

of p a r t no. 2.

c* T ransfer to the d r i l l p r e s s an d d r i l l h o l e s .

(1) Drill 5 / l 6 M hole in part no. 1, if 3/V* from

slotted end*

( 2 ) D r i l l 3/ 1 6 ” h o l e s i n p a r t n o . 2 a s p e r b l u e ­

p rin t; c o u n te rsin k 8 2 ° x 13/61^’•

d* P lace .0 1 0 shim betw een th e jaw s and b o l t jaw s

to g e th e r i n th e p o s it io n th ey w ill o c c u p y whe n

th e y a r e assem b led ,

e* Lay o u t h o l e s t o be d r i l l e d fo r h o ld in g th e

tu b in g .

f. D rill and c o u n t e r s i n k h o l e s to s iz e s sp ecified

on b l u e p r i n t .

g. Unclamp jaw s a n d rem ove .010 shim .

h. Tap h o l e s w i t h N. P . tap s; t h i s w i l l make g r o o v e s

t o k eep t u b i n g from s l ip p in g *

i. Case h a r d e n ja w s .

2. How t o m ak e s c r e w s f o r a r m s , p a r t s n o s . 3 a n d if.
 105

a. P a r t n o . 3«

( 1 ) C ut on e p i e c e o f c o ld r o l l e d s t e e l 3 / 8 ” x

3 /8 ” x 2 V V *.

( 2 ) P l a c e i n f o u r jaw c h u c k o n l a t h e and c e n t e r

a c c u r a te ly w ith 1 l / 2 ” e x te n d in g .

( 3 ) Turn dow n t o 5 / l 6 ” d i a m e t e r x 1 l /l } .” l o n g .

( 4 ) Cut 5 / 1 6 - 1 8 N. C.

( 5 ) Form 3 / l 6 M r a d i u s on t h e e n d b y m o v in g

l o n g i t u d i n a l a n d c r o s s f e e d s a t sam e tim e by

hand*

( 6 ) R e v e r s e p a r t i n c h u ck and f a c e t o e o r r e c t

le n g th .

( 7 ) G r in d o r m i l l h e a d t o c o r r e c t t h i c k n e s s *

(8 ) G r in d or m i l l r a d iu s on h e a d .

(9 ) D r i l l 3 / l 6 H h o l e 5 / 3 2 ” from th e h e a d .

3* How t o o b t a i n tw o 5 / l 6 ” w in g n u t , p a r t n o . 5»

a. Make o u t a m a t e r i a l r e q u i s i t i o n ; d e s c r i b e w in g

n u ts •

b. O b ta in t e a c h e r ' s s i g n a t u r e .

c. P resent r e q u is it io n t o s t o r e room a t t e n d a n t ,

if* How t o make t h e tw o p i n s f o r h o l d i n g s c r e w i n t h e

jaw s, p a r t n o . 6 .

a. C ut tw o p i e c e s o f d r i l l r o d 3/ 1 6 ” d i a m e t e r x 5 / 8 ”

lo n g *

b* F i l e b u rrs o f f ends w ith m i l l f i l e *

 io6

5>. How t o m ak e t h e clam p, p a r t n o . 7*

a. Cut one p i e c e of co ld ro lle d s te e l 3 /V f x 2 l / 2 ”

x 3 1 /8 ” .
b. Lay o u t a c c o r d i n g to b l u e p r i n t ; c e n te r punch

h o les to be d r i l l e d f o r rem oving s t o c k .

c. T ransfer to t h e d r i l l p r e s s a n d d r i l l h o l e s f o r

rem oving s t o c k ; d rill 1 1 /V * hole n ear c e n te r.

d. T r a n s f e r p a r t t o m i l l i n g m achine o r s h a p e r a n d

m achine p a r t t o s i z e .

e. P i l e p o r t i o n you c a n n o t m a c h in e .

f. T ra n sfe r to th e d r i l l p r e s s a n d d r i l l h o l e t o be

t h r e a d e d , u s i n g a MUn d r i l l *

g. T r a n s f e r t o b e n c h v i s e a n d t a p h o l e 7/l6**lij. N. C.

h. Case h a r d e n .0 1 0 d e e p .

i. T r a n s f e r t o s u r f a c e g r i n d e r and s u r f a c e w here

p o ssib le.

6. How t o m a k e s c r e w , p a r t n o . 8.

a. C u t one p i e c e c o l d r o l l e d s t e e l l / 2 ” x l / 2 M x

3 1 / 2 ”.

b. P l a c e i n f o u r j a w c h u c k on l a t h e and c e n t e r

a c c u r a t e l y w i t h 2/ l 1/ ’ e x t e n d i n g .

cl T u r n down t o 7 / l 6 ” d i a m e t e r x 2 ” l o n g .

d. C u t 7 / l 6 - l i j . N. • C. t h r e a d .

e. T urn s e c t i o n on th e end l / V d i a m e t e r x I / I 4.” l o n g .

 f. R everse p a r t i n chuck and f a c e to le n g th ; tu rn

l / 2 ” r a d i u s on t h e e n d by m oving l o n g i t u d i n a l and

cro ss fe e d s a t the sam e t i m e b y h a n d .

g. T ransfer p a rt to d r i l l p re ss and d r i l l the 5 / l 6 ”

h o le i n th e head and l / 8 ” h o le a t sm all end.

7. How t o m ake t h e tap ered f la r in g p in , p a rt no. 9«

a. Cut o f f one p i e c e of d r i l l rod 7 /8 ” d ia m e te r x

1 1 /2 ” long.

b. P lace i n th re e jaw u n i v e r s a l ch u ck w i t h 5 / 8 ” e x ­

ten d in g .

c* S e t c o m p o u n d r e s t a t I4.5 0 a n d t u r n 9 0 ° p o i n t .

d. R e v e rse p a r t i n chuck and f a c e t o c o r r e c t le n g th *

e* C en ter and d r i l l l / l / 1 hole 9 /3 2 ” deep.

f. T ransfer to d r i l l press and d r i l l the 1 / 8 ”

h o le f o r the p in ; co u n tersin k slig h tly .

g. T ra n s fe r to fo rg e and h ard en ; draw te m p e r to

straw c o lo r.

8. How t o m a k e t h e l / 8 ” p in , p a rt no. 10.

a. Cut a p ie c e of d rill ro d l / 8 ” diam eter xl5 /l6 ”

long.

b. P ile burrs o ff w ith a m ill file .

9. How t o m a k e t h e h a n d l e , p a r t n o . 1 1 .

a. Cut one p i e c e c o ld r o l le d s t e e l l / 2 ” diam eter x

6” lo n g .
 108

b. C e n te r ends and mount b etw een c e n t e r s on th e

lath e; d riv e w ith la th e dog.

c. Turn $ / l 6 M d ia m e te r s e c t i o n 1 3 /l6 ” lon g ; p o lish

w ith fin e a b rasiv e c lo th and o i l .

d. T h r e a d e n d 5 / l 6 - l 8 N. C. x l / i f ” l o n g .

e. P lace p a r t in th ree jaw ch u ck w i t h l a r g e end

e x ten d in g .

f. Pace to c o r r e c t l e n g th and t u r n r a d iu s b y m oving

lo n g itu d in a l and c ro ss f e e d s a t sa m e t i m e b y h a n d .

10. How t o m ake r e m o v a b l e b a l l , p a r t no. 12.

a. C ut one p i e c e o f co ld r o l l e d s te e l l / 2 M diam eter

x l / 2 M lo n g .

b. P lace in th re e jaw c h u c k , face and c e n te r d r i l l

end.

c. D r i l l h o l e w i t h f,F n d r i l l 5 / l 6 ,! d e e p .

d. T h r e a d w i t h £ / l 6 - l 8 N. C. tap.

e. S crew on e n d o f h a n d l e a n d p l a c e h a n d l e in

th ree j a w c h u c k w i t h b a l l e n d e x t e n d i n g l ?f.

f. T urn r a d i u s on b a l l b y m o v in g l o n g i t u d i n a l a n d

cross feeds a t sa m e t i m e b y h a n d .

g. P o lis h w ith f in e a b ra s iv e c l o t h and o i l .

11. How t o assem ble the f l a r i n g to o l.

a. P la c e screw s n o s. 3 4 in m illed slo ts of

jaw n o . 2; lin e up t h e 3 / l 6 n h o l e s a n d i n s e r t

3 / 1 6 11 p i n s n o . 6 .
 b* Peen ends of p in s s l i g h t l y and f i l e sm ooth*

e* P lace jaw s nos* 1 and 2 t o g e t h e r and f a s t e n w i t h

the two 5 / l 6 ,! w i n g n u t s n o .

d. T urn l / l 6 " screw i n t o h o le o f t h e clam p*

e* P lace t a p e r e d f l a r i n g p i n on e n d o f s c r e w a n d

in s e r t l / 8 M p in .

f. P e e n e n d s s l i g h t l y w i t h b a l l p e e n hammer a n d

file ends flu sh *

g* I n s e r t h a n d le i n h o le i n h e ad o f screw i n clam p,

h* Screw rem o v a b le b a l l on end of t h e h a n d le *

i* S lid e t h e clam p o v e r t h e jaw s*

B. ACTIVITY ASSIGNMENT: L a b o r a t o r y p e r f o r m a n c e s t h a t m ay

h e lp you i n c r e a s e y o u r s k i l l s i n m achine s h o p .

1* Make a f l a r i n g to o l as d ir e c te d .

2* A s s i s t someone e l s e in the c la s s in com pleting h is

flarin g to o l; p o in t out h is m istak es to him .

3. S e le c t o th e r designs of fla rin g to o ls from to o l

c a t a l o g u e s and com pare them w i t h y o u r f l a r i n g to o l.

C. EVALUATION: Some t e c h n i q u e s t h a t may b e u s e d i n c h e c k i n g

your o p eratio n s and know ledge.

1* F lare se v e ra l sh o rt p ieces of seam less tu b in g to

check r e s u l t s o f work done by t h e f l a r i n g to o l*

2* RATING SCALE: R ate y o u r s e l f a c c o rd in g t o r a t i n g

s c a l e below * G ive 1 p o i n t f o r p o o r, 2 f o r good,

3 fo r ex cellen t*

a. ( ) Y ou k e e p t o o l s sharp*

b* ( ) You u s e p r o p e r t o o l f o r t h e jo b .

c. ( ) You w o r k e n t i r e p e r i o d *

d* ( ) You u s e p r o p e r m e a s u r i n g t o o l s t o c h e c k work

e* ( } Yo u c l e a n m a c h i n e a f t e r u s i n g *

f* ( ) You f o l l o w d irectio n s i n doing a jo b .

g* ( ) You a r e q u i e t a n d o r d e r l y i n c l a s s *

( ) T o ta l.

TRUE-FALSE: P l a c e an X i n c o r r e c t s p a c e f o r answer*

T F
a* ( ) ( ) Y o u w o u l d u s e t h e sa m e s i z e d r i l l for

d rillin g a h o l e t o b e t a p p e d l / l p - 2 0 N. C

a s you would f o r d r i l l i n g a hole to be

t a p p e d l / l p —2iq. N. F .

b. ( )( ) You s h o u l d n o t u s e c o o l a n t s w h e n m i l l i n g
m etal•

c. ( )( ) A ll end m ills are r i g h t hand*

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 112

CHAPTER 2 0 . PRESSURE PUMP

HOW TO FABRICATE A DEVICE TO SUPPLY AIR
FOR KEEPING GAS TANKS UNDER PRESSURE

If it s p i t s and s p u t t e r s and you c a n 't p e e l r u b b e r

when you d i g o u t , perhaps i t ' s th at lazy c arb u reto r th a t is

h o ld in g you back. A p r e s s u r e pump i n s t a l l e d on t h a t r o d

w ill a ssu re an a d eq u a te flow of g a s, i f you h a v e ga3 i n t h e

tan k a t a l l tim es. The c h e a p e s t m e t h o d o f o b t a i n i n g a

p r e s s u r e pump h o n o r a b l y i s t o m ake o n e i n t h e m a c h i n e s h o p

class.

In sta ll the f i r s t pump a s a d e m o n s t r a t o r o n y o u r own

car, and you w i l l s o o n b e t a k i n g o r d e r s t o make t h i s h a n d y

accessory fo r a l l your frie n d s. Of c o u r s e , you r e a l i z e th at

you a l s o g a i n m u ch v a l u a b l e ex p erien ce i n d o i n g t h e man y

o p e r a t i o n s n e c e s s a r y t o make t h e pump.

A. DIRECTIONS: S t e p s y o u may f i n d u s e f u l in fa b ric a tin g a

p r e s s u r e pump. ( S e e b l u e p r i n t o f p r e s s u r e pump # 2 0 . )

1. How t o make t h e b o d y , p a r t n o . 1.

a. Cut m a t e r i a l . Use 1 3 / V * d i a m e t e r x 1 2 ” S h e l b y

S eam less T ubing.

b. I n s ta ll u n iv ersal th ree jaw c h u c k a n d c e n t e r

r e s t on th e l a t h e .

c. P lace tu b in g in chuck w ith 10” ex te n d in g , sup­

port th is end in th e cen ter r e s t.

 113
d. Pace end and c u t t h r e a d s a s p e r b l u e p r i n t .

e. T urn t u b in g end f o r end; f a c e and t h r e a d end.

f. P o lish e n tire le n g th of tube w ith a b ra s iv e c lo th

and o i l .

2. How t o make t h e c a p s , p a r t n o s . 2 a n d 3*

a. Cut m a t e r i a l . U se 2 " d i a m e t e r x 2 7 / l 6 ” c o l d

ro lle d steel. T h is w i l l be s u f f i c i e n t m a t e r i a l

fo r bo th p a rts .

b. I n s ta ll th ree jaw u n i v e r s a l ch u ck on t h e l a t h e .

c. Perform fo llo w in g o p e ra tio n s on m a t e r i a l m ounted

in the chuck;

(1 ) F a c e one e n d ; r e v e r s e i n chuck and fa c e o th e r

end. M a t e r i a l s h o u l d now m e a s u r e 2 3 / 8 ” l o n g .

(2) C en ter d r i l l one end a n d d r i l l th ro u g h w ith

19/61/’ d r i l l .

(3) S e t l a t h e f o r slow speed and ream h o le to

5/ 1 6 ".
(if.) P l a c e b o r i n g b a r i n to o l p o s t and bore h o le

1 .6 d ia m e te r x " J /l6 n deep.

(5) R e v e rse w ork i n ch u ck and r e p e a t o p e r a t i o n s

on o t h e r en d .

d. T r a n s f e r work t o a r b o r p r e s s a n d p r e s s £ / l 6 ”

• m andrel i n t o ream ed h o le . Be c a r e f u l n o t t o

sp o il th read s.

e. M ou nt w o r k b e t w e e n c e n t e r s a n d p e r f o r m t h e
 fo llo w in g o p e ra tio n s .

(1) Take a l i g h t cut to t r u e up t h e w ork.

(2) Rough t u r n p a r t s a s p e r draw ing.

(3) R o u gh o u t a n d f i n i s h tu rn rad iu s on e a c h

p art.

( Ip) F i n i s h t u r n sm all d ia m e te r s e c tio n .

(5) K nurl s e c t i o n s a s p e r b l u e p r i n t .

( 6 ) Use p a r t i n g t o o l a n d c u t c a p s a p a r t a s

sh ow n i n b l u e p r i n t .

(7) P r e s s out th e m and rel.

( 8 ) D r i l l h o l e i n p a r t 3 w i t h ”R” d r i l l a n d t a p

1 / 8 - 2 ? N. P . T.
3. How t o make t h e r o d .

a. Cut m a t e r i a l . U s e 5 / l 6 ft d i a m e t e r x l l f ” c o l d

ro lle d steel.

b. P lace i n th ree jaw u n i v e r s a l c h u c k w i t h 1 1 / 2 ”

ex ten d in g .

(1 ) Face and t r u e up end.

(2) Cut t h r e a d s a s p e r b l u e p r i n t .

c. T urn end f o r end i n chuck and r e p e a t o p e r a t i o n s .

[(.. How t o make t h e m e t a l w a s h e r s , p a r t s n o s . Ij. a n d 5*

a. Use s h e e t o f 1 / 8 ” co ld r o l l e d s t e e l .

b. D r i l l two 5 / l 6 ” h o l e s I / ' a p a r t .

c. S et hole c u t t e r a p r o p e r d ia m e te r and c u t

1 19/ 3 2 ” w a s h e r.
 H5
d. S et h o le c u t t e r and c u t 1 1 5 /3 2 ” w asher.

e. Remove b u r r s w i t h m i l l f i l e .

5. How t o o b t a i n p a r t s 6 a n d 7*

a. R e q u i s i t i o n tw o 5 / l 6 - 2 i | . N. P . n u ts from sto c k

room.

b. P u rch ase l e a t h e r w asher from l o c a l p a r ts house.

6. How t o m ake k n o b , p a r t n o . 8.

a. Cut m a t e r i a l . U se 2 ” d i a m e t e r x 1 7 / 1 & ' 1c o l d

ro lle d steel.

b. P lace in th ree j a w u n i v e r s a l c h u c k w i t h 3 /V 1

ex ten d in g .

(1) Face and c e n t e r d r i l l end.

(2) D r i l l h o le w ith " I " d r i l l 1 /2 * deep.

( 3 ) T a p 5 / l 6 - 2 l ^ N. F .

( Ip) T u r n 2 5 / 8 ” r a d i u s .

(5) F i l e and p o l i s h .
c. Screw p a r t on en d o f r o d a n d p l a c e r o d i n t h r e e

jaw c h u c k w i t h p a r t ex ten d in g .

(1) Turn r a d i u s on end.

(2) F i l e and p o l i s h a l l over.

7. How t o a s s e m b l e t h e pump.

a. Screw cap no. 3 on one e n d o f t h e b o d y .

b. S lid e r o d w i t h knob on end i n t o h o le in o th er cap.

c. Screw one n u t on end o f r o d .

d. P la c e w a sh e rs on ro d , la r g e m etal w asher f i r s t ,
 116
l e a t h e r w asher second, and th e sm all m e ta l wash­

er la st.

e. S crew s e c o n d n u t on r o d t o h o l d w a s h e r s I n p o s i ­

tio n .

f. L u b ricate in s id e w a lls o f body and s l i d e rod

w i t h w a s h e r s on e n d i n t o b o d y .

g. Screw cap on end.

B. ACTIVITY ASSIGNMENT: L a b o ra to ry perform ances t h a t may

h e lp you i n f a b r i c a t i n g p r e s s u r e pum ps.

1. F a b r i c a t e a p r e s s u r e pump a s d i r e c t e d .

2. I n s t a l l p r e s s u r e pump o n c a r .

3. L ist b e n efits d e r i v e d f r o m h a v i n g a p r e s s u r e pump o n

your car.

C. EVALUATION; S a m p l e s o f e v a l u a t i o n t e c h n i q u e s t h a t may b e

a p p lie d in co n n ectio n w ith m an ip u lativ e s k i l l s .

1. PRECISION DEVICES: U se o f e x a c t i n s t r u m e n t s t o c h e c k

work a c c o m p lis h e d .

a. Check a l l dim ensions w ith r u l e and c a l i p e r s .

b. Check r a d i u s w i t h r a d i u s g a g e.

c. Check t h r e a d s w i t h t h r e a d g a g e .

2. BEST CHOICE: P la c e t h e number o f th e b e s t answ er i n

the p a re n th eses.
 11 7
a. ( ) W hile t u r n i n g a s l e n d e r p i e c e o f s t e e l in

th e la th e , you should s e t th e to o l b it:

(1) on c e n t e r . (2) 5 ° below c e n t e r .

(3) 5 ° above c e n t e r . (Ij.) 1 0 ° a b o v e c e n t e r .

b. ( ) You s h o u l d l e a v e th e chuck key in the la th e

chuck: ( 1 ) w hen t h e m a c h i n e i s n o t i n m o t i o n .

(2 ) u n d e r no c i r c u m s t a n c e s . (3 ) w h i l e you

go t o t h e t o o l room. ( i|_) w h i l e y o u p l a c e t h e

to o l h o ld er.

c. ( ) W hile t u r n i n g work b e tw e e n c e n t e r s , you

should have th e t a i l s t o c k : (1) loose.

(2) rem oved. (3) eq uipped w ith a c e n te r

d rill. (I|_) w e l l l u b r i c a t e d .
 118

t.6QS
ii

S
is

D ETAIL D RAW IN G p/eessu/ee p u m p 5 P 0 P J O ® A/*

S C A L E */* * / " &LoePAtNT N 8 Z &
 CHAPTER 2 1 . BENCH VISE
HOW TO CONSTRUCT A TOOL FOR HOLDING WORK WHILE
I T I S BEING FINISHED OR ASSEMBLED AT THE BENCH

C a llin g a l l s t u d e n t s w i t h home . w o r k s h o p s 1 Here i s the

a n s w e r t o t h a t ” d r e a m ” come t r u e . T his bench v i s e is a

”m u s t ” f o r y o u a n d s h o u l d t a k e p r i o r i t y o v e r o t h e r equipm ent

you i n t e n d to s e c u r e fo r your shop. The m o s t i m p o r t a n t

facto r is t h e f a c t t h a t y o u c a n m ake t h i s v ise in class

th is sem ester.

F r i e n d s w i l l be amazed when y o u t e l l t h e m y o u m ad e

the v is e a t sch o o l and e x p la in th e low c o s t of th e to o l.

Your f a t h e r w i l l a p p r e c i a te h a v in g such a f i n e tool in the

shop. If y o u do n o t h a v e a home w o r k s h o p , th ere is a ready

m arket f o r th e v i s e , and you can r e a l i z e a p ro fit i f you

m ake i t to se ll. You w i l l g a i n v a l u a b l e e x p e r i e n c e i n the

v a rie ty of o p eratio n s r e q u i r e d i n m akingt h i s to o l.

A. DIRECTIONS: S te p s w hich m ig h t a s s i s t you i n m aking th e

bench v is e . (See b l u e p r i n t s of t h e b e n c h v i s e # 2 1 , $21A,

#21B, #21C, # 2 ID, # 2 I E . )

1. How t o m a k e t h e jaw s, p a r t s n o s. 1 a n d 2*

a* C u t t w o p i e c e s of 1M x 3 l / 2 ” x 3 5 / l 6 ” co ld

ro lle d steel*

b* P lace sto ck i n v ise on t h e m i l l i n g m achine*

 120

(1) M ill ends to c o r r e c t le n g th *

(2 ) M i l l o f f s e t 1 ” w id e x 1 . 8 ” deep*

(3) M ill cham fers as p e r b l u e p r i n t ,

c* T ran sfer sto ck to th e work b e n c h .

(1) Lay o u t and c e n t e r pun ch l o c a t i o n s f o r a l l

holes to be d r i l l e d .

( 2 ) C la m p p a r t s to g e th e r and d r i l l a l l h o les

th ro u g h b o th p a r t s w ith a #10 d r i l l .

(3) S e p a ra te p a r t s , d rill, ream , and t a p a l l

h o le s as p e r b l u e p r i n t .

2* How t o make t h e v ise s c r e w , p a r t n o . 3*

a. C u t o f f onep i e c e of 1” d ia m e te r x 6 3 / l 6 ” c o ld

ro lle d steel.

b. P lace i n th r e e jaw chuckj fa c e and c e n t e r d r i l l

ends •

c. Mount work b e t w e e n c e n t e r s .

(1 ) Turn a l l diam eters to c o r r e c t s i z e .

(2) Set lath e a n d c u t 5 / 8 - 1 1 N. C. - 2 t h r e a d .

(3 ) Cham fer l a r g e e n d a s p e r b l u e p r i n t .

d. D r i l l h o l e s a s shown a f t e r screw cap h a s b een

m ade a n d f i t t e d over end.

3* How t o m a k e t h e 2 v i s e g u i d e s , p a r t n o . 4*

a. C ut two p i e c e s of l l / l 6 ” diam eter x 5 3 /1 6 ” co ld

ro lle d steel.
 121

b* P lace in l a t h e chuck; face and c en ter d r i l l ends*

c. Mount w ork b e tw e e n c e n t e r s *

(1) Turn a l l d iam eters to size*

(2) Cham fer l a r g e e n d l / l 6 u x if5°*

(3) P o l i s h w ith a b r a s iv e c l o t h and o i l .

if. How t o m a k e t h e v i s e screw c a p , p a r t n o . 5>.

a. C u t o f f one p i e c e o f 1 l / 8 Hd ia m e te r x 1 $ / l 6 n

c o ld r o l le d steel,

b* P lace s t o c k i n ch u ck on t h e l a t h e *

( 1 ) F a c e e n d a n d c h a m f e r 3 / l 6 " x lf5>°.

(2) T urn e n d f o r e n d i n t h e chuck*

(3) Face and c e n t e r d r i l l end.

(if.) D r i l l a n d r e a m * 6 2 5 h o l e 1® d e e p ,

c* P l a c e cap on v i s e screw *

(1) D r i l l #13 h o le fo r3 /l6 " p in .

(2 ) D r i l l 25/61fM h o l e .

How t o m ake t h e vise base, p a rt no. 6.

a. Cut s t o c k 5 / l 6 Mx 2 7 / 8 ” x use h o tr o lle d steel,

b. Lay out base as p e r b l u e p r in t.

c. G rind or m ill r a d i i .

d. Lay o u t, c e n te r punch, and d r i l l t h e $ / l 6 nh o l e s ,

e* F i n i s h g r i n d on s u r f a c e g r i n d e r *

6* How t o m a k e v i s e h a n d l e , p a r t n o . 8.

a. Cut a p ie c e of 3/8" diam eter x 6 l / l 6 n co ld

ro lle d steel*
 122

b. P l a c e work i n t h r e e jaw chuck*

(1 ) Turn ends t o c o r r e c t diam eter and n e c k a s p e r

b lu ep rin t.

(2) S e t l a t h e f o r th re a d in g and cut th re a d on

each end.

7. How t o m ak e t h e 2 t h r e a d e d b u s h i n g s , p a r t n o . 7*

a. C u t two p i e c e s o f 5 / 8 fl d i a m e t e r x 3/V* c o l d

ro lle d s te e l.

b. P lace i n th re e jaw c h u c k .

(1) Paee end and c e n t e r d r i l l .

(2) D r i l l ttF w h o l e t h r o u g h p a r t .

(3) Tap 5 / l 6 M- l 8 N. C.
(if) C o u n t e r b o r e 3 / 8 M x 3 / 8 M.
c. Screw b u s h in g s on en d s o f v i s e h a n d l e .

d. P lace han d le i n th ree jaw c h u c k w i t h b u s h i n g

ex ten d in g .

(1 ) Take a l i g h t t r u i n g - u p c u t .

( 2 ) C h a m f e r e n d l / l 6 M x l}-50 *

(3) T u r n h a n d l e e n d f o r e n d i n t h e c h u c k a n d
m a c h i n e t h e o t h e r b u s h i n g t h e sa m e a s t h e

first.

8* How t o m a k e t h e s p a c e r , p a r t n o . 9*

a. Cut a p i e c e o f l/V * x l w x 3 M c o ld r o l l e d ste el.

b. G rind l / 2 ” ra d iu s on each end.

 123
c* Lay o u t a n d c e n t e r p u n c h p l a c e s f o r h o l e s ,

d. D rill and c o u n te rsin k th e h o le s .

9. How t o m ak e t h e jaw i n s e r t s , p a r t no. 10.

a. C ut two p i e c e s of l / V x 1 M x 3 9 / l 6 ff c o l d

ro lle d s te e l.

b. P lace p a r ts in v ise on t h e m i l l i n g m a c h in e .

(1) T rue up e n d s and m achine to c o r r e c t le n g th .

(2) M ill s e r r a t i o n s as p e r b l u e p r i n t.

c. Lay o u t h o l e s t o be d r i l l e d .

( 1 ) C lam p i n s e r t s in place on t h e jaw s.

(2) L o c a te h o l e s to be d r i l l e d w i t h d u p l i c a t i n g

punch.

d* D r i l l h o le s w ith #7 d r i l l a n d t a p l / l f - 2 0 N. C.

10 . How t o a s s e m b l e t h e b e n c h v i s e .

a. W eld s t a t i o n a r y ja w t o v i s e b a s e .

b. P r e s s v i s e g u id e s i n t o $ / Q n ream ed h o l e s o f the

m ovable jaw ; d r i l l h o les and i n s e r t 3 / l 6 H p in s .

c. S lid e d r ille d end o f v is e screw i n t o 5 /8 M h o le

betw een g u id e b a r s .

d. P ress v is e sc re w c a p on end o f v i s e screw and

in s e r t a 3 / l6 H p in .

e. A ssem ble v i s e h a n d le in hole in v is e screw cap.

f* Screw th e v ise screw i n t o the tapped h o le i n the

s t a t i o n a r y jaw , a t t h e sa m e t i m e s l i d i n g th e v ise
 12k

g u i d e s i n t o Jp/8H r e a m e d h o l e s ,

g# P lace sp a c e r over ends of v is e g u id es and peen

the ends o f th e g u i d e s ,

h. M ount j a w i n s e r t s on jaw s a n d f a s t e n w i t h l / i j .- 2 0

f i l l i s t e r h e a d screw s#

B. ACTIVITY ASSIGNMENT; Work f o r y o u t o a c c o m p l i s h i n p e r ­

f e c tin g your a b i l i t y to co n stru ct a v ise .

1# Make a b e n c h v i s e as d ire c te d .

2. Make a l i s t o f c h a n g e s y o u w o u l d m ake t o i m p r o v e t h e

vise#

G. EVALUATION: S a m p l e s o f some t y p e s o f c h e c k - u p s w h i c h

m ay b e a p p l i e d t o your p r o j e c t .

1. PRECISION DEVICES: Use o f e x a c t i n s t r u m e n t s t o

c h e c k w ork#

a. Check d im e n s io n s w i t h a s t e e l r u l e #

b# Check a n g l e s w i t h a p r o t r a c t o r #

c# Check t h r e a d s w i t h a t h r e a d g a g e .

2# COMPLETION: W rite in th e lo n g b lan k s ahead o f th e

item s th e answ ers t h a t sh o u ld be in the s h o r t to k e n

b l a n k s w i t h i n t h e item s#

a# ___________________ You s h o u l d u s e a ______ to set the

th read in g to o l p erp en d icu lar to

th e w ork.
b. The o u t s i d e d i a m e t e r o f a 5 / 8 - 1 1

N. C . t h r e a d i s ______ •

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 132

CHAPTER 2 2 . ADJUSTABLE TAP WRENCH

HOW TO CONSTRUCT AN ADJUSTABLE WRENCH .
FOR TURNING TAPS

Many p e o p l e p r e f e r a n a d j u s t a b l e ta p w rench f o r h o l d ­

in g ta p s to c u t i n t e r n a l .th re a d s. Some o f t h e r e a s o n s f o r

th is preference a re because you can: use th e w rench f o r a

v ariety ofsiz e s of tap s; a p p l y more p r e s s u r e s i n c e th e to o l

p r o v id e s hand g r i p s f o r b o th hands i n th e ta p p in g o p e r a tio n ;

a l s o u se t h i s w rench f o r t u r n i n g hand re a m e rs, tap e x tra c ­

to rs, and e a sy o u ts.

A. DIRECTIONS: The f o l l o w i n g s te p s w i l l g u id e you i n con­

s t r u c t i n g an a d ju s ta b le ta p w rench. (See b l u e p r i n t o f

ad ju sta b le ta p w rench # 2 2 . )

1. How t o m ak e t h e a d j u s t a b l e sle ev e , p a r t no. 1.

a. Cut s t o c k l o n g e n o u g h f o r t h e sle e v e and th e

body com bined; th is req u ires a p iece o f co ld

ro lle d s t e e l 3 / k u d i a m e t e r x 10 1 /if.” l o n g .

b. P lace sto c k in l a t h e chuck and p e rfo rm th e

fo llo w in g o p e ra tio n s:

(1) Face and c e n te r d r i l l end.

(2) A d ju st m a te r i a l to have 3 1 / 2 ” e x te n d in g

out of th e chuck.

(3) A d ju s t th e t a i l s t o c k to s u p p o r t th e end o f

th e w ork.
 133
(If) T u r n s m a l l s e c t i o n t o 5 / 8 ” d i a m e t e r x 1 / 2 ”

long.

(5) Turn l a r g e s e c tio n to 2 1 /3 2 ” d iam eter x 2 1 / 8 ”

long.

(6) K nurl l a r g e d iam eter s e c tio n .

(7) D rill in to end o f work w i t h d r i l l m ounted i n

tailsto ck spin d le.

( 8 ) T ap h o l e t o s i z e ; su p p o rt and g uide th e ta p

w ith the t a i l s t o c k cen ter.

(9) Cut o f f work w i t h p a r t i n g t o o l , allo w in g

enough sto c k f o r f i n i s h i n g th e end.

(10) P lace sleev e in the chuck, u sin g sh eet b ra s s

to p r o te c t the k n u rle d s e c tio n .

( 1 1 ) P a c e end a n d c h a m f e r 3 / 3 2 x lf5°-

2. How t o m ake t h e b o d y , p a r t n o . 2.

a. Use rem ain d er o f 's t o c k a lr e a d y c u t.

b .P la c e w ork i n t h r e e jaw c h u c k .

(1) Pace end and c e n t e r d r i l l .

(2 ) H e v e rs e t h e work i n th e chuck; f a c e end to

l e n g t h and c e n t e r d r i l l .

(3) D r i l l e n d 2 3 / 6 if” x 2 7 / 8 ” d e e p a n d r e a m . 3 7 5 -

(If) C o u n t e r s i n k h o l e 1 7 / 3 2 ” x 6 0 ° .

c. M ou n t w o r k b e t w e e n c e n t e r s .

(1) Turn a l l diam eters to c o rre c t size.

(2) Turn 3 / 8 ” r a d i u s a t th e sh o u ld ers.

 13k
(3) K nurl 2 ” s e c t i o n as p e r b lu e p r i n t .

(I|_) C h a m f e r e n d 3 / 3 2 ” x k $ ° •
(5) T u rn work en d f o r en d on c e n t e r s an d c u t

th read s to f i t ad ju stin g , sle ev e .

d. T r a n s f e r work t o th e m i l l i n g m achine.

(1) M ill f l a t sid es o f cen ter sectio n .

(2) M ill 1 /1 6 ” s l o t 5 / 8 ” lo n g .

e. T r a n s f e r w ork t o the bench.

(1 ) L a y o u t a n d c e n t e r p u n c h l o c a t i o n o f 7/ 1 6 ”
hole in c e n te r s e c tio n .

(2) D r i l l 7 /1 6 ” h o le .

(3) P i l e 90° n o tc h as p e r b l u e p r i n t .
f. T r a n s f e r work t o t h e l a t h e an d p o l i s h m achined

surfaces.

g. T r a n s f e r work t o th e forge.

(1) Case h a r d e n c e n t e r s e c t i o n .

( 2 ) Draw t e m p e r t o p u r p l e co lo r.

3- How t o make t h e p l u n g e r , p a r t no. 3-

a. U s e 1 / 2 ” x 1|- 5 / 8 ” d r i l l rod; th is allo w s 5/1 6 ”

on e a c h end f o r re m o v in g c e n t e r h o l e s .

b. P lace sto ck in th ree jaw c h u c k ; fa c e and c e n t e r

d rill ends.

c. M ount w o r k b e t w e e n c e n t e r s .

(1) T urn d ia m e te rs t o c o r r e c t size.

(2) Pace sh o u ld e r to le n g th .
 -1 3 5
(3) P o l i s h w ith a b r a s i v e c l o t h and o i l f o r

slid in g fit i n ream ed h o le i n body.

d. P la c e work i n t h r e e jaw c h u c k w i t h s m a l l d i a m e t e r

e x t e n d i n g 1*' a n d f a c e end to len g th , rem oving

c e n te r h o le.

e. R e v e rs e work i n t h e c h u c k .

(1) Face la r g e diam eter s e c tio n to le n g th r e ­

m oving c e n t e r h o l e .

(2) Turn 31° a n g le .

f. T r a n s f e r work to the bench.

(1) F ile 9 0° n o t c h on s m a ll end.

( 2 ) F i l e [(.5° a n g l e s o n s m a l l e n d .

(3) Lay o u t and c e n te r p u n c h h o le f o r p i n .

(If.) D r i l l h o l e f o r p i n , u s i n g a #53 d r i l l .

g. T r a n s f e r work t o t h e f o r g e .

(1) H arden 1 H b a c k from s m a ll end.

(2) Draw t e m p e r t o p u r p l e c o l o r .

l|_. How t o m ake t h e s p r i n g , p a r t no. If..

a. Use 18 g a g e p i a n o w i r e .

b. Cut a p i e c e o f co ld r o l l e d s t e e l l/lf.” d i a m e t e r

x 3 1 / 2 H long.
(1) C enter d r i l l one end.

(2) D r i l l a # 6 6 h o l e 1 1 / 2 11 f r o m o t h e r e n d .

(3) P lace t h i s end i n chuck and su p p o rt c e n te re d

end w ith t a i l s t o c k c e n t e r .
 c. Run p i a n o w i r e t h r o u g h h o l d e r a n d t h r o u g h # 6 6

h o le in th e rod.

d. B e n d e n d o v e r so i t w i l l n o t s l i p o u t.

e. Set lath e fo r c u ttin g l e f t hand t h r e a d s 6 th r e a d s

p e r inch.

f. Set la th e on s l o w s p e e d a n d w ind s p r i n g same a s

c u ttin g th read s.

g. Remove s p r i n g a n d c u t t o size.

h. H arden and tem per s p r i n g .

5- How t o a s s e m b l e t h e a d j u s t a b l e tap w rench.

a. S lid e spring on p l u n g e r .

b. C u t l / l 6** d r i l l ro d 5 / l 6 M lo n g and f o r c e in th e

hole in the p lu n g e r.

c. S lide th e p lu n g e r i n t o th e ream ed h o le o f th e

b o d y ; make s u r e t h e p i n slid es in to th e s l o t cut

fo r th is purpose.

d. Screw t h e sleev e on t h e b o d y ; a d ju st to f i t the

tap .

B. ACTIVITY ASSIGNMENT: L a b o r a t o r y work t o be a c c o m p l i s h e d .

1. Make a n a d j u s t a b l e tap w rench as d i r e c te d .

2. Tap s e v e r a l h o l e s , u sin g th e a d ju sta b le ta p w rench

and th e uTn t a p w r e n c h ; w rite a list of th e advantages

of each.
 137
C. EVALUATION: Methods that may be used to check jour pro­

g r e s s and u n d e r s ta n d i n g o f th e t o o l s you have i n th e

shop.
1. PRECISION DEVICES: Use o f e x a c t in stru m en ts to check

work.

a. Check d im e n s io n s w i t h a s t e e l r u l e and m ic ro m e te r

c a lip e rs.

b. Check r a d i i w i t h a r a d i u s g a g e .

c. Check t h r e a d s w i t h a t h r e a d g a g e .

2. TRUE-FALSE: P la c e an X in c o r r e c t space f o r answ er.

T F
a. ( )( ) You should n o t i f y th e in stru cto r if you

f i n d a m achine o u t o f a d ju s tm e n t o r i n

need o f r e p a i r .

b. ( )( ) You should n o t r e v e rs e th e ta p u n t i l you

have com pleted ta p p in g th r e a d s in a h o le.

c. ( )( ) You sh o u ld r u n th e m achine a t a slow

speed f o r ream ing o p e r a t i o n s .

3. COMPLETION: W rite in th e lo n g b la n k s ahead of th e

item s th e answ ers t h a t sh o u ld be in th e s h o r t to k e n

b lanks w ith in th e item s.

a. _______________ You s h o u l d u s e a _______ t o d r i v e

w ork m ounted b e tw e e n c e n t e r s .

b. _______________ You s h o u l d g r i p th e c a lip e r s lig h t­

l y t o g e t t h e c o r r e c t ______ o r

f e e l of the to o l.
 138

You c a n do a b e t t e r job o f p o l i s h ­

i n g b y u s i n g ______ e m e r y c l o t h

t h a n b y u s i n g new e m e r y c l o t h .
 139

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CHAPTER 2 3 . COMBINATION LAYOUT SET

HOW TO MAKE A SET OP TOOLS CONSISTING OP
HAMMER, CENTER PUNCH, AND SCRATCH AWL

I n o r d e r t o do y o u r l a y o u t w o r k p r o p e r l y , you need

th ree to o ls: a hammer, a c e n te r punch, and a s c r i b e r . Much

t i m e w i l l b e s a v e d i f y o u m ak e a c o m b i n a t i o n s e t c o n t a i n i n g

a ll th ree of th ese to o ls. You may make t h i s s e t a s one o f

y o u r p r o j e c t s i n t h e m achine shop c l a s s .

You n o t o n l y a c q u i r e a v a l u a b l e t o o l i n m aking t h i s

p ro jec t, you a l s o g a in e x p e rie n c e i n d r i l l i n g , tap p in g ,

th rea d in g , a n d r e a m in g on t h e l a t h e . As some p a r t s a r e made

of c o ld r o lle d s t e e l a n d some o f t o o l s t e e l , you g a in e x p e r i ­

ence i n m achining b o th ty p e s o f m a t e r i a l . T he p a r t s made

from t o o l s t e e l r e q u i r e h a r d e n i n g a n d t e m p e r i n g so you w i l l

also gain exp erien ce in th ese o p eratio n s.

A. DIRECTIONS: Some s u g g e s t i o n s t h a t w i l l a s s i s t y o u i n

m aking t h e c o m b in a tio n l a y o u t s e t . (See b l u e p r i n t o f

com bination la y o u t set #23. )

1. How t o m ake t h e h e a d , p a r t n o . 1.

a. Cut a p i e c e of 7 /8 n diam eter x 3 1 /V ! to o l steel

i n t h e p o w e r h a c k sa w .

b. Pace and c e n t e r d r i l l b o th ends i n th e u n i v e r s a l

chuck.

c. Mount w o r k b e t w e e n c e n t e r s on t h e l a t h e .
 (1) T u r n w o r k down t o 3 / V * d i a m e t e r .

(2) Lay o u t c e n t e r l i n e , u ndercuts, and ends as

per b lu ep rin t.

(3) U n d ercu t s e c t i o n s r e q u i r e d ; use 3 /3 2 ” ra d iu s

t o o l t o c u t r a d i i a s shown.

(if.) P o l i s h e n t i r e su rfa c e w ith a b ra siv e c lo th

and o i l .

d. P l a c e work i n the u n iv e r s a l chuck; use s o f t

copper to p ro te c t fin is h e d surfaces.

(1) Face end t o l a y o u t l i n e and round c o rn e rs

s l i g h t l y w ith a f i l e .

(2 ) R e v e rs e work i n t h e c h u c k ; fa c e end to l a y ­

out lin e , a n d ro u n d c o r n e r s on second face.

e. T r a n s f e r work t o t h e l a y o u t b e n c h ; lay o u t and

c e n t e r p u n c h h o l e t o be d r i l l e d .

f. S e t up i n d r i l l p r e s s .

(1) Check t o see t h a t c e n t e r l i n e of th e head i s

p e rp e n d ic u la r to th e d r i l l and in p o s i t i o n

so h o le w i l l b e i n t h e c e n te r of th e head.

( 2 ) D r i l l 19 /6if.H a n d r e a m £ / l 6 n h o l e f o r h a n d l e .

2. How t o m ake t h e h a n d l e , p a r t no. 2.

a. Cut a p i e c e o f 5 / 8 ,r d i a m e t e r x 7 1 / 8 11 c o l d r o l l e d

steel.

b. P lace in u n iv e rs a l chuck; face and c e n t e r d r i l l

b o th ends.
c. Mount i n l a t h e b e t w e e n c e n t e r s .

(1) T u r n down s t o c k t o l / 2 H in diam eter fo r

e n tire len g th .

(2) Lay o u t h a n d le a c c o r d i n g t o b l u e p r i n t .

(3) T urn s e c t i o n on end t o .313 d i a m e t e r 5 / 8 n

long.
(!}.) S e t t a p e r a t t a c h m e n t f o r 5 / l 6 ,f t a p e r p e r f t .

and t u r n t a p e r e d p o r t i o n t o r e q u i r e d d ia m e te r.

( 5 ) T u r n I4.5 0 b e v e l .

( 6 ) R e v e rs e t h e work i n t h e l a t h e an d k n u r l

h a n d l e w i t h medium k n u r l .

d. P la c e h an d le in u n iv e r s a l chuck; p r o te c t k n urled

s e c tio n w ith copper.

( 1 ) D r i l l 1 7 / 6 1 / h o l e 2 3/If." d e e p .

(2) D r i l l 5 / l 6 " h o le 5 /8 " deep.

(3) Tap 3 / 8 - 1 6 N. C. th re a d in end o f h a n d le .

How t o make t h e c e n t e r p u n c h , p a r t n o . 3-

a. Chuck a l e n g t h o f l / 2 " d r i l l rod in u n iv e rs a l or

co llet chuck, allo w in g i t to ex ten d about l / 2 n.

( 1 ) T u r n down s e c t i o n 1 /If." d i a m e t e r x 2 *’ l o n g .

(2) S e t c o m p o u n d r e s t f o r 1 l / 8 lf t a p e r p e r f t .

and t u r n lo n g t a p e r .

(3) S e t c o m p ou nd r e s t a t 3 0 ° a n d t u r n 6 0 ° p o i n t ,

(if.) E x t e n d r o d a b o u t 1 l / 2 ” m o r e o u t o f c h u c k .

(5) T u r n l / 8 ,f n e c k t o l /l f ." d i a m e t e r w i t h p a r t i n g
 Iif3
to o l.

( 6 ) Turn 3 / 8 ” d ia m e te r s e c t i o n .

(7) Set la th e and t h r e a d s on 3 /8 " sectio n . Test

th re a d s in h an d le.

( 8 ) K nurl head o f punch.

(9) C ham fer one en d o f k n u r l e d s e c t i o n .

(10) Cut t o l e n g t h w i t h p a r t i n g t o o l .

b. P la c e k n u rle d s e c t i o n in chuck; p r o t e c t k n u rl

w ith s o f t copper.

(1) Face and cham fer end.

(2) C e n te r end and d r i l l #30 h o l e 1 7 / 8 ” deep.

(3) D r i l l #25 h o le f o r th r e a d .

(Jj.) T h r e a d #10 -2lf. w i t h t a p .

(5) P o l i s h w ith a b ra s iv e c l o t h and o i l .

c. H arden and tem per.

I4.. How t o make t h e s c r a t c h aw l, p a r t no. !{..

a. Chuck a l e n g t h o f 7/1 & ” d r i l l rod in u n iv e r s a l

o r c o l l e t chuck w ith about 2 ” ex te n d in g from th e

chuck.

( 1 ) T u r n down t o .190 d ia m e te r x 1 5 /8 " lo n g .

(2) S e t compound r e s t fo r tap erin g 1 /2 ” per f t .

and t u r n ta p e re d sectio n .

(3) S e t compound r e s t a t 6 0 ° a n d t u r n 3 0 ° p o i n t .

(Ij.) T u r n 1 / 8 ” n e c k t o 1 / 8 ” d i a m e t e r ; use p a rtin g

to o l.
 ili4

(5) E x t e n d f r o m c h u c k a b o u t 3 / V ’ m o r e a n d k n u r l
end.

( 6 ) U n d e r c u t e n d o f k n u r l a s sh ow n i n b l u e p r i n t .

(7) T h r e a d s e c t i o n w i t h # 1 0 - 2 h. d i e .

(8) L ay o u t l e n g t h o f awl an d c u t t o l e n g t h w i t h

p a rtin g to o l.

b. P la c e awl i n u n i v e r s a l chuck.

(1) F i l e end ro u n d w i t h m i l l f i l e .

(2) P o l i s h w ith a b r a s i v e c l o t h and o i l .

c. H a rd en a n d draw t e m p e r .

d. How t o a s s e m b l e t h e com bination s e t.

(1) P re s s handle i n t o h e a d on a r b o r p r e s s .

(2 ) Lay o u t , d rill and ream h o l e f o r # 5 -0 t a p e r

p in so t h a t p i n w i l l s e t flu s h w ith head.

(3) P la c e t a p e r p i n i n h ead and ta p w ith b r a s s

hammer.

(ij.) S c r e w p u n c h i n t o h a n d l e a n d a w l i n t o p u n c h .

B. ACTIVITY ASSIGNMENT; S u g g e s te d w ork t o be done i n th e

shop.

1. Make a c o m b i n a t i o n l a y o u t set as d irected .

2. Make a l i s t o f s h o r t c u t s t h a t may b e u s e d i n m a k i n g

th is p ro ject.
 11*5

C. EVALUATION: Samples of evaluation techniques that may­

be used in e v a lu a tin g your a c t i v i t i e s .

1. PRECISION DEVICES: Use o f e x a c t i n s t r u m e n t s t o c h e c k

work.

a. Check d im e n s io n s w i t h a s t e e l r u le and m icro m eter

c a lip e rs.

b. Check a n g le s w ith a p r o t r a c t o r .

c. Check t h r e a d s w i t h a thread gage.

d. Check r a d i i w i t h a r a d iu s gage.

2. TRUE-FALSE: P lace an X in th e c o r r e c t space f o r

answ ers.

T F
a. ( )( ) You should use the c ro ss fee d to cut

ta p e rs req u ired .

b. ( )( ) You should s e t t h e p a r t i n g t o o l t o c u t on

cen ter.

c. { )( ) You should h e a tm etal to a c h erry red to

tem per i t .

3. RATING SCALE: P la c e an X i n e a c h sp a c e f o r w hich y o u r

p ro ject i s co m p letely c o r r e c t acc o rd in g to d ir e c tio n s

•giv en .

a. ( ) D iam eters.

b. ( ) T hreads.

c. ( ) R ad ii.

d. ( ) T apers.
) K nurl

) T o tal
 147

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 CHAPTER 2 I4.. CONFEDERATE CANNON
HOW TO FABRICATE A MODEL 1 2 - L B . BRONZE
MUZZLE LOADING HOWITZER

Many o f y o u h a v e p a r e n t s o r f r i e n d s who n e e d o r n a m e n t s

for th e ir den or f o r o th e r p la c e s a b o u t t h e home. T h is

c a n n o n w i l l m ak e a n e x c e l l e n t g i f t f o r t h e s e p e o p l e . In r e ­

turn, you w i l l r e c e i v e many c o m p l i m e n ts f r o m v i s i t o r s and

rela tiv e s f o r m aking s u c h an i n g e n i o u s o rn a m e n t.

The g u n w i l l f i r e b a l l s from b a l l - b e a r i n g r a c e s , al­

though i t is dangerous i f overcharged. The p r o p e r c h a r g e ,

if the b a r r e l i s added w e ll, is powder rem oved from t h r e e

I / I 4." f i r e c r a c k e r s . A f u s e a b o u t 1 l / 2 tt l o n g sh o u ld be used*

I n a d d it i o n to th e s e rew ards, you g a in e x p e r ie n c e i n

ta p e r tu rn in g , d r i l l i n g , ream ing, a n d c o n t o u r t u r n i n g on t h e

lath e. You w i l l a l s o u s e t h e m i l l i n g m a c h i n e o r s h a p e r i n

m aking t h e tru n io n s*

A. DIRECTIONS: H elpful h in ts f o r f a b r ic a tin g th e co n fed er­

a te cannon. ( S e e b l u e p r i n t o f c a n n o n #2lj.. )

1. How t o m a k e t h e t r u n i o n s , p a r t n o . 1.

a. M o un t s h o r t sc ra p sto c k i n u n i v e r s a l chuck o r

c o l l e t w ith 1M ex te n d in g .

(1) Turn t o dim ensions and p o l i s h .

(2) Cut o f f p a r t w ith p a r t i n g to o l.

(3) P la c e p a r t i n t h e chuck and f a c e t h e e n d .

b. S et asid e the p re s s i n t o th e b arrel la te r.

How t o m ake t h e b a r r e l , p a rt no. 2.

a. Cut a p ie c e o f l w‘ d i a m e t e r x $ 5 / l 6 ,f b r a s s .

b. Chuck s t o c k i n in d e p e n d e n t chuck and tr u e u p .

(1) Pace and c e n t e r d r i l l end.

(2) D r i l l out w i t h a lo n g d r i l l and ream to s i z e .

(3) R ev erse i n th e chuck and cen ter d r i l l o th er

end.

c. M ount w o r k b e t w e e n c e n t e r s .

(1 ) Rough t u r n c a s c a b e l .

( 2 ) S e t t a p e r a t t a c h m e n t f o r l / 2 1’ p e r f t . or

offset tailsto ck 3 /32".

(3) Turn b a r r e l t o d i m e n s i o n s on b l u e p r i n t .

(ij.) Pace shoulders and muzzle.

d. C lam p b a r r e l i n a V b l o c k a n d l a y o u t p o s i t i o n s for

t r u n i o n s , u s i n g s u r f a c e gage and c e n t e r p u n c h .

e. D r i l l a n d ream 3 / 8 ” h o l e s l / 8 ” deep w i t h a d r i l l

ground to a l i p a n g l e o f 80 d e g r e e s .

f. C en ter punch and d r i l l fuse h o le .

g. Press tru n io n pin s in p lace.

h. Chuck i n u n i v e r s a l c h u c k .

( 1 ) R ound up c a s c a b e l .

(2) P o l i s h a l l over.

How t o make t h e c a n n o n m o u n t s , p a r t n o . 3*

a. C u t tw o l e n g t h s a n g l e s t e e l 3 / l 6 w x 1 l / 2 ” x 1 l / 2 f*
 150

b. Lay o u t t o d im e n s io n s and r o u g h c u t w i t h h a n d

h a c k saw*

c* M o u n t i n s h a p e r v i s e a n d make a n g u l a r c u t s to

size*

d* C en ter punch and d r i l l a ll h o les.

e* D ra w f i l e edges and c le an o f f b u r r s .

f. P ain t w ith f l a t black ,

if. Howt o m ake t h e b a s e .

a. Cut base of w alnut to size, 3 /ifw x 3 1 / 2 ” x

6 l / 2 ”.
b. Cut c h am fers.

c. Lay o u t a n d d r i l l shallow sp o ts f o r 5 / l 6 tt b a l l s .

d. Lay o u t a n d d r i l l 7/32” h o les fo r fa s te n in g

cannon m ount.

e. Sand sm ooth, co at w ith la c q u e r, r u b down w h e n

dry, and p o l i s h w i t h wax.

f. Cut a s t r i p o f 2 0 - g a g e b r a s s 3/ I 4.” x 3 ” , a n d

sta m p “C o n f e d e r a t e C annon” on i t . P o lish th is

p late and f a s t e n to base w ith e sc u tc h e o n p i n s .

if. Howt o a s s e m b l e t h e c a n n o n .

a. A ssem ble c an n o n mount and b a r r e l .

b. F a s te n c an n o n t o b a se w ith f o u r l / l f ” by 1 ” l a g

screw s.

c. P ile four b a lls in p o sitio n .

 151

B. ACTIVITY ASSIGNMENT: Work t h a t s h o u l d b e d o n e i n t h e

shop t o make y o u p r o f i c i e n t i n f a b r i c a t i n g the C onfeder-

a te cannon*

1* F a b r i c a t e a model C o n f e d e r a te cannon as d i r e c t e d .

2. D e sig n a model C o n fe d e ra te c an n o n , u s in g w h eels t o

mount i t i n s t e a d of tr u n io n s .

C. EVALUATION; T echniques u se d to e v a l u a t e your p e rfo rm a n c e .

1. PRECISION DEVICES: Use o f e x a c t i n s t r u m e n t s t o check

w ork.

a* Check d im e n s io n s w i t h a s t e e l r u l e and c a l i p e r s .

b. Check r a d i u s w i t h r a d i u s gage.

c. Check t a p e r w i t h p r o t r a c t o r .

2. TRUE-FALSE: P lace an X in the c o r r e c t space f o r

answ er.

T F
a. ( )( ) You s h o u l d r u n t h e l a t h e a t a h i g h e r

speed fo r tu rn in g b ra ss th a n f o r tu rn ­

ing s t e e l .

b. ( )( ) You s h o u l d u s e o i l f o r l u b r i c a t i n g a n d

co o lin g th e d r i l l when d r i l l i n g b r a s s .

c. ( )( ) S t e e l w ould be more a p p r o p r i a t e f o r the

base of th e cannon th an b la c k w a ln u t.

3» RATING SCALE: P lace an X i n e a c h s p a c e f o r w h i c h

your p r o j e c t i s c o m p le te ly c o r r e c t according to
 152

directions given.

a. ( )Cannon bore is smooth.

b. ( )Fuse is drilled in proper place at the base

of the bore*

c. ( ) Trunion pins are in line, horizontally and

vertically.

d. ( )The cannon and base are highly polished.

e. ( )The cascabel is symmetrical.

( ) Total*
 153

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 151*.
CHAPTER 2 5 . SMALL SCREWDRIVER
HOW TO MAKE A TOOL FOR TURNING SMALL SCREWS

T h i s s m a l l s c r e w d r i v e r w i l l be u s e f u l i n m aking

r e p a i r s on t h e s m a l l e r a p p l i a n c e s a r o u n d t h e h o m e. You

f e l l o w s who own c a r s a n d m o t o r s c o o t e r s w i l l f i n d t h i s a

h a n d y t o o l t o h a v e when y o u h a v e t o a d j u s t o r o v e r h a u l y o u r

carb u reto r.

A v a r i e t y o f s k i l l s w i l l be u t i l i z e d , such as f o r g i n g ,

rad iu s tu rn in g , th read in g , h ardening, and tem p erin g .

A. DIRECTIONS: S tep s th a t w ill enable y o u t o make a s m a l l

screw d riv er. (See b lu e p rin t o f screw d riv er # 2 5 .)

1. How t o make t h e h a n d l e , p a r t n o . 1.

a. C u t o f f a p i e c e o f l / 2 f* x 2 l / l 6 ,f h e x a g o n c o l d

ro lle d steel.

b. P l a c e i n u n i v e r s a l c h u c k a n d t u r n r a d i u s o n one

end.

c. R e v e rse work i n chuck w i t h 1" e x te n d in g o u t o f

th e chuck.

(1) Face and c e n t e r d r i l l end.

(2) D r i l l #21 h o le 1" deep.

(3) C o u n t e r b o r e 3 / l 6 !l x 1 / 8 ,! d e e p .

(If) Threadh o le w ith #10-32 ta p .

(5)Turn 5 / 8 ” r a d i u s as per b lu ep rin t.

 d. T r a n s f e r work t o t h e d r i l l p r e s s .

(1) Lay o u t and d r i l l l/l6 " h o l e a s shown.

(2) C o u n t e r s i n k s l i g h t l y on e a c h e n d .

2. How t o make t h e b l a d e , p a r t no. 2.

a. Cut o f f a p i e c e o f #10 d r i l l rod 3 l / 2 ” long.

b. Forge end a s p e r b l u e p r i n t .

c. F i l e and g rin d to shape.

d. Saw b l a d e t o c o rre c t len g th .

e. T h r e a d e n d # 1 0 - 3 2 a s sh o w n .

3. How t o a s s e m b l e t h e screw d riv er.

a. Screw b l a d e in to h an d le.

b. D r i l l l / l 6 ” h o le th ro u g h th e th re a d e d s e c tio n .

c. Cut a l / l 6 ” p i n 1 3 / 1 3 2 '’ l o n g and d riv e it in to

th e h o le.

d. Peen each end o f th e p i n and f i l e en d s sm ooth.

e. P o lis h a l l over.

B. ACTIVITY ASSIGNMENT: Work t h a t w i l l a s s i s t y o u i n so lv ­

i n g p ro b le m s c o n n e c te d w i t h m aking t h e sm all s c re w d riv e r.

1. Make a s m a l l s c r e w d r i v e r a s d i r e c t e d .

2. Make a s m a l l s c r e w d r i v e r , u s in g round s t o c k f o r th e

h an d le; k n u rl th e han d le f o r e asy h o ld in g .

 156

C. EVALUATION; C h e c k - u p s t h a t may b e a p p l i e d t o y o u r w o r k .

1. PRECISION DEVICES: U se o f e x a c t i n s t r u m e n t s t o c h e c k

work.

a. Check d im e n s io n s w i t h s t e e l ru le.

b. Check r a d i i w i t h r a d i u s g a g e .

2. BEST ANSWER: P la c e th e number of th e b e s t answ er in

th e p a re n th e se s.

a. ( ) The h a n d t o o l y o u s h o u l d u s e f o r t h r e a d i n g

th e hole i n th e h an d le i s : (1) a ta p .

(2) a d ie. (3) a t h r e a d g ag e. (Ip) a s e t

screw .

b. ( ) When f o r g i n g t o o l s t e e l , you should h e a t th e

m etal to : (1) w h ite h e a t . (2) cherry red.

(3) y e llo w h e a t . ( !p) 1 0 0 0 ° F .

 157

H anole kJ wuRi . or Wc*

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S C A L E F S .D . BLUEPRINT U~ Z S
 158

CHAPTER 2 6 . SINGLE POINT SCRIBER

HOW TO MAKE A TOOL TO BE USED TO MARK OR EAT OUT WORK

Would y o u l i k e to have a t o o l w ith w hich t o increase

t h e a c c u r a c y o f y o u r l a y o u t work? I f you w ould, you should

make t h i s sin g le p o in t scrib er. T h is h an dy t o o l can be

c a r r i e d a r o u n d i n y o u r p o c k e t f o r u s e a t s c h o o l o r a t home.

I t w i l l b e a welcome a d d i t i o n t o y o u r t o o l k i t a n d c a n be

made b y f o l l o w i n g t h e d irec tio n s below .

A. DIRECTIONS: H e l p f u l h i n t s f o r m aking t h e sin g le point

scrib er. (See b l u e p r i n t o f t h e sc rib e r # 2 6 .)

1. How t o make t h e c o l l e t n u t, p a r t no. 1.

a. Cut o f f a p i e c e o f 1 / 2 " d i a m e t e r x If. l/If." long

co ld r o l le d ste el; th is w i l l make t h e n u t and

the h an d le .

b. P lace m a te ria l in a th re e jaw u n i v e r s a l c h u c k

w ith 1" e x te n d in g .

(1) Face and c e n t e r d r i l l th e end.

(2) T urn to 3 / 8 n d ia m e te r x l l / l 6 " long.

(3) D r i l l 1 /8 " h o le 5 /8 " deep.

(If.) D r i l l 3/ 8 " d e e p w i t h " I " d r i l l .

(5) D r i l l to p ro p er d ep th w ith s p e c ia l d rill

s h a r p e n e d a t l± $ ° a n g l e .

(6) Tap w i t h 5 / l 6 " - 2 5 N. F . tap .

(7) K nurl.

( 8 ) U se p a r t i n g t o o l a n d c u t o f f 9 / l 6 M l o n g .

P lace p a rt in th re e jaw c h u c k ; p r o t e c t k n u r l w i t h

sheet brass.

(1) Pace end.

(2) Turn tap er.

(3) P o l i s h .

t o make t h e h a n d l e , p a r t no. 2.

Use r e m a i n d e r o f s t o c k c u t f o r n u t .

P lace the sto c k i n a u n iv e rs a l th re e jaw c h u c k ;

fa c e and c e n te r d r i l l en d s.

Mount s t o c k b e t w e e n c e n t e r s .

(1) Turn e n tire len g th down t o 3 / 8 ”d i a m e t e r .

(2) Turn sectio n to be th re a d e d to .005 under­

size, a llo w in g 5 / l 6 n f o r rem oving th e cen ter

h o le.

( 3 ) Neck a s p e r b l u e p r i n t .
(ij.) S e t l a t h e a n d c u t 5 / 1 6-2if. N. F . thread.

(5) K nurl s e c t i o n 2 3 /8 " lo n g .

P l a c e work i n t h r e e jaw c h u c k w i t h t h r e a d e d end

ex ten d in g . P ro te c t k n u rled s e c tio n w ith sh eet

brass.

(1) D r i l l 1 / 8 ” h o le 2 5 / l 6 ” deep.

(2) Face o f f 5 / l 6 M a llo w e d f o r rem oving c e n t e r

h o le.
 i6 o
(3) S e t compound r e s t a n d t u r n an g le.
e. T u rn work end f o r end i n t h e ch u ck .

(1) Cut o f f t o c o r r e c t l e n g t h .

(2) Turn r a d i u s on t h e end.

f. T ransfer p a rt to th e m i l l i n g m achine.

g. In sta ll d i v i d i n g h e a d on t a b l e of m iller.

h. M o u nt u n i v e r s a l c h u c k o n d i v i d i n g h e a d .

i. In sta ll slittin g saw o n a r b o r o f m i l l e r ,

j. A l i g n sa w w i t h h a n d l e t o be m i l l e d .

k. M ill s l o t s .

3- How t o make t h e p o i n t , p a r t n o . 3*

a. Use 1 / 8 ” d r i l l r o d .

b. P la c e m a t e r i a l in c o l l e t chuck or u n iv ersal

th ree jaw c h u c k .

(1) Turn t a p e r a s p e r d raw ing.

(2) P i l e t a p e r to f i n e p o i n t .

(3) P o l i s h w ith f i n e a b r a s i v e c lo t h and o i l .

(Ij.) C u t o f f a n d c h a m f e r e n d .

(5 ) H arden and draw te m p e r p o i n t ,

if. How t o a s s e m b l e the scrib er.

a. I n s e r t p o in t in 1 /8 ” h o le in h an d le.

b. Screw t h e n u t on end o f t h e h a n d l e .
 l6 l

B. ACTIVITY ASSIGNMENT: Work t o do t o make y o u p r o f i c i e n t

i n m aking s c r i b e r s .

1. Make a s i n g l e p o i n t s c r i b e r a s d i r e c t e d .

C. EVALUATION: T e c h n i q u e s t h a t may b e u s e d i n c h e c k i n g y o u r

progress.

1. PRECISION DEVICES: Use o f e x a c t i n s t r u m e n t s t o c h e c k

work.

a. Check d im e n s io n s w i t h a s t e e l ru le and c a l ip e r s .

b. Check t h r e a d s w i t h a t h r e a d g a g e .

MATCHING: P la c e th e number o f th e a rticle in the

p a r e n t h e s e s b e f o r e th e s ta te m e n t to w hich i t b e lo n g s .

a. ( ) C u ttin g o ff. 1. N on-ferrous.

b. ( ) M a rk in g o f work t o 2. A nnealing.

fu ll size. 3 .' C o u n tersin k in g .

c. ( ) S o f te n in g m e ta l by k- T em pering.

h eatin g , fo llo w ed by 5. L aying o u t.

g rad u a l co o lin g . 6. P artin g to o l.

d. ( ) A m etal th a t does

not co n ta in iro n .
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 163
CHAPTER 2 ? . FENDER HAMMER
HOW TO MAKE A TOOL FOR REPAIRING DAMAGED FENDERS

The f e n d e r ha mm er i a i n d i s p e n s a b l e f o r r e p a i r i n g

d e n te d or m a s h e d - in f e n d e r s on y o u r e a r o r m o to r s c o o t e r .

Y ou s h o u l d m ake o n e o r m o r e o f t h e s e h a m m e r s t o k e e p a r o u n d

t h e g a r a g e a t home.

You may u s e c o l d r o l l e d s t e e l and e a s e h a rd e n th e

faces o r use t o o l s t e e l w h ich you s h o u ld h a rd e n an d te m p e r.

E i t h e r o f t h e s e w i l l g iv e you v a l u a b l e e x p e r ie n c e i n work­

in g w i t h and h a r d e n in g m e t a l s .

A. DIRECTIONS1 S teps t h a t may b e f o l l o w e d i n m a k i n g t h e

f e n d e r hammer. ( S e e b l u e p r i n t o f t h e f e n d e r hammer # 2 7 . )

1. How t o make t h e hammer h e a d .

a. Cut m a t e r i a l 1 l / 2 M d i a m e t e r x £ l / V lon g to o l

steel or co ld r o lle d steel.

b. P lace m a te r ia l in u n iv ersal th ree jaw ch u ck ;

face and c e n t e r d r i l l ends.

c. Mount b e tw e e n . c e n t e r s .

(1) T urn e n t i r e le n g th to 1 7 / l 6 M diam eter.

(2) Turn a l l d iam eters to s iz e ; a l l o w 3 / 8 ,f on

e a c h end t o remove c e n t e r h o l e s . Turn t h e s e

s e c t i o n s t o 3/ 8 " d i a m e t e r .

(3 ) Turn r a d i i as r e q u i r e d .
 i6l}.

d. T r a n s f e r t h e work t o t h e m i l l i n g m a c h in e .

e. P l a c e t h e d i v i d i n g h e a d on t h e m i l l .

f. P lace a sla b m ill on t h e arbor.

g. Mount t h e p a r t b e tw ee n c e n t e r s .

(1) M il l one s i d e o f s q u a r e e n d .

(2 ) T u rn d i v i d i n g h e a d h a n d l e 10 r e v o l u t i o n s .

(3) M ill seco n d s i d e of square.

( 14-) M i l l o t h e r s i d e s i n sam e m a n n e r .

h. T r a n s f e r work t o l a t h e and c u t o f f s e c tio n s w ith

cen ter h o les.

i. T r a n s f e r w ork to t h e b e n c h .

(1) L ay o u t h o le 3 / 8 ” x 5 /8 " »

(2) D r i l l tw o 3 / 8 ” h o l e s 3 / l 8 ’* a p a r t .

(3) P i l e h o le to s iz e ,

j. Harden and tem per f a c e s .

2. Plow t o a s s e m b l e h a m m e r .

a. P u rc h a s e wooden h a n d le fro m t o o l room.

b. Sand h a n d le t o f i t h o l e i n ha m m er h e a d .

c. D rive handle in to the h ead .

B. ACTIVITY ASSIGNMENT: Work t o d o i n t h e s h o p .

1. Make a f e n d e r ham m er a s d irec te d .

2. R e p a i r damaged f e n d e r hammers i n th e t o o l room.

3* E x am in e d e s i g n s o f f e n d e r hammers i n s e v e r a l t o o l

catalo g s; w rite i n s t r u c t i o n s f o r m aking a f e n d e r

 ha m m er t h a t w i l l s u i t y o u r n e e d s ,

C. EVALUATION: M e t h o d s t h a t m ay b e u s e d t o check y o u r

f e n d e r hammer,

1. PRECISION DEVICES: Use o f e x a c t i n s t r u m e n t s to

check w ork.

a. Check a l l d i m e n s i o n s w i t h s t e e l r u l e according

to the b l u e p r i n t ,

b* Check r a d i i w i t h r a d i u s g a g e .

2. RATING SCALE: P lace an X i n the s p a c e f o r w h ic h

you q u a l i f y .

a. ( ) You f o l l o w e d p r o c e d u r e o u t l i n e d i n t h e

d ire c tio n s and read the b l u e p r i n t .

b. ( ) You c u t m a t e r i a l r e q u i r e d f o r m a k i n g t h e

hammer h e a d a n d r e t u r n e d r e m a i n d e r o f t h e

m aterial to th e sto c k ra c k .

c. ( ) You u s e d s o l u b l e o i l a s a c o o l a n t when

m i l l i n g t h e p a r t on t h e m i l l .

d. ( ) You t u r n e d o f f g a s b e f o r e t u r n i n g blow er

o f f when s e c u r i n g t h e f o r g e .

( ) T o tal.
 166

D E T A tL D P A W /N G SH O P JOB N ? Z 7
SCALE r . S . D. FENDER. H A M M E R B L J E P Z / M T N°- Z 7
 CHAPTER 2 8 . FLEX HANDLE
HOW TO MAKE A SOCKET WRENCH FLEX HANDLE WITH A 3 / 8 " DRIVE

S t u d e n t s who h a v e s o c k e t sets th a t req uire a 3 /8 ”

d riv e s h o u l d make t h i s f l e x h a n d l e i n l i e u o f the f l e x hand le

in C hapter l6 . T h is t o o l w i l l be u s e f u l f o r t u r n i n g a v a r i e ­

ty of so ck ets and attach m en ts. I t w i l l be a c o n v e n i e n t t o o l

f o r use i n o v e rh a u lin g a c a r or m otor s c o o te r .

E x p e r i e n c e w i l l be g a in e d i n o p e r a t i n g t h e f o l l o w i n g

equipm ent: lath e, d rill press, m i l l i n g m achin e, and v a rio u s

hand to o ls .

A. DIRECTIONS: P o i n t e r s t h a t w i l l g u id e you i n m aking th e

f l e x h an d le. (See b l u e p r i n t o f t h e f l e x h a n d le # 2 8 . )

1. How t o make t h e b o d y , p a r t n o . 1.

a. Cut one p i e c e o f 3 / k ” d i a m e t e r x 9 3 / k ■" s p r i n g

ste el.

b. Mount m a t e r i a l i n t h r e e jaw u n i v e r s a l chuck;

fa c e and c e n t e r d r i l l b o th ends.

c. Mount t h e w o r k b e t w e e n c e n t e r s .

(1) R ou g h t u r n a l l d iam eters.

(2) Rough t u r n 3 / 8 " r a d i i .

(3) F i n i s h t u r n d ia m e te rs t o size.

(ij.) F i n i s h t u r n 3 / 8 " r a d i i .

(5) K nurl s e c t i o n f o r hand g r i p .

 168
(6) Cham fer k n u r l e d end l / l 6 " x I4.5 0 .

d. T r a n s f e r work t o m i l l i n g m ac h in e .

(1) M ill f l a t s i d e on t h e . h e a d .

(2) R evo lv e t h e work 9 0 ° and m i l l t h e 3 / 8 " slo t

l l / l 6 ” long.

(3) M ill t h e 5 /1 6 " r a d i u s on th e end.

e. T r a n s f e r t h e work t o the d r i l l p r e s s , d rill the

3 /l6 " h o le, and c o u n te rs in k th e h o le 7/ 3 2 " x 8 2 ° .

f. D rill the l / 8 " h o le f o r sp rin g and b a l l . (Pur­

chase th e sp rin g s and s te e l b a lls from a p a r t s

h o u se .)

2. How t o make t h e d riv e, p a r t no. 2.

a. Cut a p i e c e o f 3 / 8 ” x 9 / l 6 " x 1 I / I 4." t o o l steel.

b. P lace in v ise on t h e m i l l i n g m a c h in e .

(1) M i l l 5/ 16 ” r a d i u s on t h e e n d .

(2) M i ll o p p o s i t e end to 3 /8 " square.

c. T r a n s f e r w ork t o the d r i l l p r e s s .

(1) D r ill l / 8 n ho le fo r sprin g and b a l l .

(2) D r i l l th e 3/1 6 " h ole.

(3) D r i l l d i m p l e on th e end.

3- How t o a s s e m b l e t h e h a n d l e .

a. P lace s p rin g s and s t e e l b a l l s in h o les d r ille d

f o r them and s e t them i n p l a c e w i t h a d im p lin g

to o l.

b. Cut a p i e c e o f 3/ 1 6 " d r i l l rod 1 l / l 6 " long.

 169
B. ACTIVITY ASSIGNMENT: Work to be done to increase your

p r o fic ie n c y in th e u se of th e lath e and t h e m i l l i n g

m ach in e.

1. Make a f l e x h a n d l e a s d i r e c t e d .

2. A s s i s t one o f .y o u r c l a s s m a t e s i n m aking a f l e x h a n d l e .

C. EVALUATION: T e c h n i q u e s t h a t m ay b e u s e d t o c h e c k y o u r

w ork.

1. PRECISION DEVICES: Use o f e x a c t i n s t r u m e n t s t o

c h e c k work a c c o m p lis h e d .

a. M easure a l l p a r t s w i t h a s t e e l r u l e .

b. Check r a d i i w i t h r a d i u s g a g e .

2. RATING SCALE: P la c e an X i n e a c h space f o r w hich

you q u a li f y .

a. ( ) You r e a d t h e b l u e p r i n t b e f o r e a t t e m p t i n g t o

do a j o b .

b. ( ) You f o l l o w e d a d v i c e g i v e n i n t h e d i r e c t i o n s
sectio n .

c. ( ) You o b e y e d s a f e t y r u l e s when o p e r a t i n g t h e

m achines.

d. ( ) You u s e d a c o o l a n t w h e n o p e r a t i n g t h e m i l l i n g

m ach in e.

e. ( ) You w e r e r e a d y t o b e g i n w o r k i m m e d i a t e l y

a f t e r a t t e n d a n c e was c h e c k e d .

( ) T o tal.
 170

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 171
ANNOTATED BIBLIOGRAPHY

A. BOOKS

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T h is book p r e s e n t s a p r a c t i c a l m ethod f o r l e a r n i n g
m achine shop work by p r e s e n t i n g a c t u a l p ro b lem s and
g iv in g d i r e c t i o n s f o r s o lv in g th e problem .

2. B ench W ork. A lbany, New Y o r k : D elm ar P u b l i s h e r s , In c .,

1946•
A b a s i c t e x t w h i c h d e s c r i b e s t h e t h e o r y o f B e n c h W ork
and t h e o p e r a t i o n s p e r f o r m e d w i t h m e a s u r i n g , l a y o u t a n d
bench to o ls*

3* B e n n e t t, C h a r le s A ., H i s t o r y o f M anual and I n d u s t r i a l
E d u c a t i o n up to 1 8 7 0 . P e o r i a , I l l i n o i s : The M a n u a l
A r t s P r e s s , 1926* ]J6l pp*

An i n t e r e s t i n g b o o k c o v e r i n g t h e h i s t o r i c a l de v elo p* *
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in d u s tr ia l e d u catio n .

ij_. B en n ett, C h arles A ., A H i s t o r y o f M anual and I n d u s t r i a l

E d u catio n , I 87O t o 1917. P eo ria, I l l i n o i s : The M a n u a l
A r t s P r e s s , 1937* 5>°6pp*

5>* . B u r g h a rd t, H enry D ., M achine T o o l O p e r a t i o n , P a r t I .

New Y o r k a n d L o n d o n : M c G r a w - H i l l Book C o m p an y, 1 9 1 9 *
!f20 p p .

A t e x t b o o k f o r m a c h in e sh o p s t u d e n t s c o n t a i n i n g much
e x c e l l e n t m a t e r i a l p e r t a i n i n g to t h e l a t h e , b e n c h work
and work a t t h e f o r g e . S hould be r e v i s e d .

6. B u r g h a r d t , H enry D . , M achine T ool O p e r a t i o n , P a r t I I *

New Y o r k a n d L on d on :, The M c G r a w - H i l l Book C om pany,
1919. 512 p p .

A t e x t b o o k f o r m a c h in e shop s t u d e n t s w i t h i n s t r u c t i o n s
on d r i l l s , s h a p e r s , p l a n e r s , h y d r a u l i c s , and g e a r s .
S hould be re v is e d *
 172

7* Colem an, G eorge J . , F o rg e N ote Book* M ilw au k ee: The

B r u c e P u b l i s h i n g C o m p an y, 1 9 2 1 . 26 pp.

A re fe re n c e book g iv in g th e n e c e s s a ry in fo rm a tio n r e ­
g a rd in g the t o o l s , o p e r a tio n s , and p r o c e s s e s u sed in
f o r g e w ork.

8. C o lv in , F re d H ., and S t a n l e y , F ran k A ., A m erican

M a c h i n i s t s 1 Handbook. New Y o r k a n d L o n d o n : McGraw-
H i l l Book Company I n c . , 1 9 3 5 - l l l *6 p p .

An e x c e l l e n t r e f e r e n c e b o o k o f m a c h i n e s h o p a n d d r a w i n g
room d a t a , m e th o d s a n d d e f i n i t i o n s .

9. C o u rse i n M achine Shop - P a r t 1 ; Bench and D r i l l P r e s s

W ork. S acram ento: C a l i f o r n i a S t a te D epartm ent of
E d u c a t i o n , 19l*7* 94- PP*
A workbook f o r a p p r e n t i c e s i n th e m a c h i n i s t s 1 t r a d e .
D e s i g n e d t o b e u s e d b y a p p r e n t i c e s w o r k i n g on t h e j o b ,
g iv es d ir e c tio n s f o r study in o th e r books.

10. C o u rse i n M achine Shop - P a r t 2 ; S h a p e r a n d L a t h e W ork.

Sacram ento: C a l i f o r n i a S t a te D epartm ent o f E d u c a tio n ,
191*8. 57 P P .

T h is i s a workbook f o r a p p r e n t i c e m a c h i n i s t s , g i v e s
d i r e c t i o n s f o r s t u d y and l i s t s m a t e r i a l s f o r s t u d y .

11. C o u rse i n M achine Shop - P a r t 3 : M i l l i n g M achine and

P l a n e r W ork. S acram ento: C a l i f o r n i a S t a t e D epartm ent
o f E d u c a t i o n , 191*8. 5 6 p p .

T h is i s a workbook f o r a p p r e n t i c e m a c h i n i s t s , g i v e s
d ir e c tio n s fo r study and l i s t s m a te r ia ls f o r stu d y .

12. D r i l l P r e s s W ork. A lbany, New Y o r k : D elm ar P u b l i s h e r s ,

I n c . , 19l*8• 1*2 p p .
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p r e s s e s ; u s e s o f a c c e s s o r i e s and h o ld in g d e v ic e s ; c u t ­
t i n g s p e e d s a n d f e e d s ; a n d a l l o p e r a t i o n s p e r f o r m e d on
the d r i l l p r e s s .

13 * F a c ts About Taps a n d T a p p in g . G r e e n f i e l d , M a s s .:
G r e e n f i e l d T ap a n d D i e C o r p . , 1 9 3 8 . 128 p p .

T h is book i s an e x c e l l e n t r e f e r e n c e t o h e l p p e o p le
in te r e s te d in tap p in g to s e le c t th e p ro p er tap s f o r t h e i r
req u irem en ts•
 173
llj.. G ro e b li, Jo h n M .; M e talw o rk in g F u n d a m e n ta ls , S anta
B arbara, C a lifo rn ia ? P a c i f i c E d u c a t i o n a l P r e s s , 1 9^4-8 .
67 PP*
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lev el#

A G u id e f o r Young M a c h i n i s t s # P r o v i d e n c e , R. I . :
Br own a n d S h a r p e M a n u f a c t u r i n g C om pany , I 9 I4-O. 3 1 7 PP*

A good r e f e r e n c e m anual f o r b e g in n in g m a c h i n i s t s . Con­

t a i n s many h e l p f u l i l l u s t r a t i o n s , d i a g r a m s , a n d t a b l e s .

16# Handbook f o r D r i l l e r s . C lev elan d , O hio; The C l e v e l a n d

T w i s t D r i l l C o m p an y, 1 9 4 8 .

An e x c e l l e n t m a n u a l f o r u s e i n s h o p s a n d t r a d e s c h o o l s
to te a c h s tu d e n ts the th e o ry u n d e rly in g th e use o f th e
tw ist d r i ll .

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N o r t o n Company, 1 9 3 8 . 1 7 7 PP*

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a p p re n tic e i n th e p r o p e r s e l e c t i o n and u se o f g r in d in g
w h e e ls , a n d t o f a m i l i a r i z e him w i t h t h e p r i n c i p l e s and
m ethods o f g r i n d i n g v a r io u s ty p e s o f t o o l s and c u t t e r s .

18• H a r p e r , R o b e r t F r a n c i s , T h e Code o f H a m u r a b i , K i n g o f
B abylon. C hicago; The U n i v e r s i t y o f C h i c a g o P r e s s ,
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I n t e r e s t i n g r e f e r e n c e book p e r t a i n i n g t o B ab y lo n ian
la w s a n d c u s to m s a b o u t 2250 B .C .

19* L a t h e W o r k . A l b a n y , New Y o r k ; D elm ar P u b l i s h e r s , In c .,

T9I4BT l b i f p p .

A co m p reh en siv e t e x t c o v e rin g th e r e l a t e d t e c h n i c a l

in f o r m a tio n and fundam ental p r o c e s s e s w hich a re b a s i c
f o r l a t h e w ork h e l d b e tw e e n c e n t e r s and i n a ch u ck .

20. M achine Shop M e a s u re m e n t. A l b a n y , New Y o r k ; D elm ar

P u b l i s h e r s , I n c . , 1946* 65 p p .

A b e g i n n e r 's te x tb o o k w hich c o v e r s b a s i c m a th e m a tic a l

p r i n c i p l e s o f l i n e a r , c i r c u l a r , and a n g u la r m easurem ent
from t h e s t a n d p o i n t o f r e l a t e d m a th e m a tic s and m achine
shop p r a c t i c e .
 17k
21« Manual o f L a th e O p e r a t i o n and M a c h i n i s t T a b l e s .
K alam azoo, M ic h ig a n : A t l a s P r e s s Com pany, 1 9 3 7 * 237 p p .

An e x c e l l e n t b o o k o f i n s t r u c t i o n s o n how t o o p e r a t e a
lath e. C o n ta in s v a l u a b l e t a b l e s and i n t e r e s t i n g d ia g ra m s .

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23. O 'B rie n , J . J . , a n d O ' B r i e n , M. W . , How t o R un a L a t h e .

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A m anual of i n s t r u c t i o n s f o r o p e ra tin g and m a in ta in in g

a m odern g e a r e d head e n g in e l a t h e .

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26 . S m i t h , R o b e r t H ., A d v a n ce d M a ch in e W ork. , B oston, M ass.:

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A t e x t b o o k p r e p a r e d f o r s t u d e n t s i n t r a i n i n g t o become
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 B . PERIODICALS

H u n t , D e W i t t , ’’T he P r o f e s s i o n a l i z a t i o n o f I n d u s t r i a l
A r t s T e a c h i n g , H A m erican V o c a t i o n a l J o u r n a l , 2 3 : 9 ,
O c t o b e r , 19i|-8*

P i c k e r e l l , R. E . , a n d B a r k e r , G l e n , wB e n c h V i s e , ”
S c h o o l S h o p , 7 : 7 » J a n u a r y , 1 9 I4.8 .

UNIVERSITY OF SOUTHERN CALIFORNIA UBRABX