DESIGN

SKETCHING

All designs use drawings. Some people are very good at drawing, some less so. But sketching is still an important part of conveying the information you need to get across.

DEMONSTRATION (NOT ASSIGNMENT)

ASSIGNMENT #1
SKETCH 5 THINGS THAT ARE IN THE ROOM

#NO-NUMBERS #NO-LETTERS #JUST-DRAWINGS

All projects, concepts, and design ideas come from a set of drawings or plans. Good plans will be more than a sketch. Since you will be working with drawings to start, or creating drawings for the higher levels, you need to be able to READ a drawing.

ALL PAGES MUST HAVE A BORDER with a TITLESTRIP and YOUR FIRST AND LAST NAME on it.

NEXT UP:

There are two types of drawings that we typically use: Isometric, and Orthographic. They each have their purpose.

ISOMETRIC SKETCHING

LESSON

This style of drawing is best used to show what the completed object LOOKS LIKE.  It sucks to WORK FROM.

Some people cannot visualize things – this drawing is best for those people to SEE what you’re going to build.

Both the left and right sides come off at a 30° angle to give it a more realistic appearance (but it will look slightly distorted – no “perspective”). This is the hardest to draw.

You want to show the VIEW with the MOST DETAIL. You want no details “hidden.”

Notice the arrangement of each view on the sheet below. These views show the MOST information of the object.  If you were to look at the object from any other angle, you would NOT be showing useful information.

DEMONSTRATION (NOT ASSIGNMENT)

ASSIGNMENT #2

THIS IS NOT TRACING – Kindergarten is over, move on. AT NO TIME will I EVER accept TRACED drawings. THIS IS NOT TRACING. Accept it.

LEVEL 0 Draw any 2 (two) objects shown BELOW in Isometric Format	LEVEL 1 Draw any 6 (six) objects shown BELOW in Isometric Format	LEVEL 2 Draw any 6 (six) objects shown BELOW in Isometric Format BUT ROTATED SO YOU SEE THE OTHER SIDE	LEVEL 3 Draw a detailed Isometric view of the Major Project you want to build this year.
CLICK HERE to print TRIANGLE CHEATING PAPER, which you will place underneath a blank piece of paper to act as a guide. CLICK HERE to print the GEOMETRIC SHAPES – Count the flats of the triangles. EVERY PAGE MUST HAVE a two-grid space BORDER (all drawings must have a border) and a two-grid TITLE STRIP (all drawings must have a title strip) at the bottom for your NAME, the DATE, and the TITLE. MARKS: If you pick the easy ones, I will mark you hard; if you pick the hard ones, I will mark you easy. If it is not a correct Isometric Format, I won’t mark it. I generally take 1 mark off for each mistake. If the drawings are not done “good enough” (at least 70%) I won’t mark it at all. But I will help you to make them better. I do not mark garbage; don’t give me garbage.

ORTHOGRAPHIC SKETCHING

LESSON

These drawings are ALWAYS used in plans and designs and blueprints.  These are THE BEST for FABRICATION. You need to be able to read these.

They are, however, are harder for some people to visualize the finished product.

The object is drawn with three separate views (Top, Side, End) that are “projected” off of each other.

“Projected” means that the TOP VIEW IS DIRECTLY ABOVE THE SIDE VIEW, and that the END VIEW IS DIRECTLY BESIDE THE SIDE VIEW.

• • They are absolutely 100% directly in line
  • The LENGTH is the same on the SIDE and TOP views
  • The WIDTH is the same on the TOP and END views
  • The HEIGHT is the same on the SIDE and END view
  • Anything different is wrong; I don’t care how you feel about it

Kind of like drawing on a box, and then unfolding the box. This is the hardest to type of drawing to understand.

DEMONSTRATION (NOT ASSIGNMENT)

UNIQUE TO ORTHOGRAPHIC DRAWINGS: Hidden details (like holes and edges on the opposite side or inside) are show as a DASHED LINE. Stuff that IS THERE, but you CANNOT SEE, are drawn in a dashed (hidden) line.

TWO OF THESE ARE DRUNK:

THE VIEWS MUST LINE UP!

THE SIZE BETWEEN VIEWS MUST BE CONSISTENT

ASSIGNMENT #3

THIS IS NOT TRACING – Kindergarten is over, move on. AT NO TIME will I EVER accept TRACED drawings. THIS IS NOT TRACING. Accept it.

LEVEL 0 Draw any 2 (two) objects shown BELOW in Orthographic Format	LEVEL 1 Draw any 6 (six) objects shown BELOW in Orthographic Format	LEVEL 2 Draw any 3 (three) objects shown BELOW in Orthographic Format BUT SHOW ALL 6 SIDES	LEVEL 3 Draw a detailed Orthographic view of the Major Project you want to build this year.
CLICK HERE to print RECTANGLE CHEATING PAPER, which you will place underneath a blank piece of paper to act as a guide. CLICK HERE to print the GEOMETRIC SHAPES – Count the flats of the triangles. EVERY PAGE MUST HAVE a two-grid space BORDER (all drawings must have a border) and a two-grid TITLE STRIP (all drawings must have a title strip) at the bottom for your NAME, the DATE, and the TITLE. MARKS: If you pick the easy ones, I will mark you hard; if you pick the hard ones, I will mark you easy. If it is not a correct Orthographic Format, I won’t mark it. I generally take 1 mark off for each mistake. If the drawings are not done “good enough” (at least 70%) I won’t mark it at all. But I will help you to make them better. I do not mark garbage; don’t give me garbage.

DIMENSIONING

LESSON

All Manufacturing and Fabrication Industries depend on Drawings. Without Drawings, nothing can be manufactured. We’ve looked at Drawings. Now we need to look further.

The “drawings” that companies use to “Work” from are called “Working Drawings.” A Working Drawing must have enough information that someone could build the object as specified.

A Working Drawing must:

• • Have all the views you need to explain the shape
  • Have all the dimensions and specifications you need to build the object
  • Have the actual materials listed

ASK YOURSELF: “Can this object be built without further instructions?”

The more things you build, the more you will be able to know what needs to be listed. You will know what you need to know, bro.

There are rules; there is a way Dimensions are given:

• • Edges and locations of components are indicated by EXTENSION LINES that extend off (but do not touch) the object.
  • Measurements are positioned between arrows, the arrows will extend from the actual number, TO the extension lines.
  • Dimension lines ARE NOT ON THE OBJECT – they are a distance away.
  • Dimension the object on the view that shows the most information
  • Usually dimension BETWEEN the views, and to the RIGHT SIDE of the view.
  • HOLES are measured by DIAMETER, because DRILLS are measured by DIAMETER
  • ROUNDED CORNERS are measured by RADIUS, because you need to set your compass to the circle’s RADIUS to draw it.
  • OVERALL Dimensions are always on the OUTSIDE
  • NEAT AND TIDY!.

Example:

WORKSHEET

In class, I usually lead you through the filling out of this worksheet:

CLICK HERE to print the Dimensioning Notes Worksheet, and make each shape look like the one below:

ASSIGNMENT

CLICK HERE to print the Dimensioning Assignment Worksheet, and FOLLOW THE NOTES ABOVE to dimension the shape.

MARKS : “Competency” – You will receive full marks when this is dimensioned adequately.

Is it kicking your butt?

DO IT yourself first, then if you have to…. watch this Video Solution (it doesn’t have to be exactly as shown, but you should show enough information).

SAFETY, TOOLS, MACHINES

You might not want to watch this:

Level 0 WORKSHEET to go with Level 0 POWERPOINT

Level 1-3 WORKSHEET to go with Level 1-3 POWERPOINT

You must pass a SAFETY QUIZ with AT LEAST 80%

The Quiz is on THESE NOTES and MACHINE DEMOS

ASSIGNMENT – Safety Booklet

The Purpose….

In this activity you will be producing a word processed handout on the safety of a machine. This should be review, however it’s been a long summer, and most of our brains have turned into mush, so we may need a refresher.

The Procedure…

You will work in groups set up by your Instructor. Each group will be randomly given a topic for which they must present an exactly 2 (two) page handout. The handout will describe each safe operation of the machine such that anyone in the class will be able to understand. Use Google to find your information.

The handout must contain the following:

To make it easier, follow these easy steps (You will find this course MUCH easier if you will take the time to read the instructions!):

Research the topic – gather as much information as you can

Select the Need to Know basic safety

Outline the steps needed to operate the machine safely, or to perform the task

Organize the information into a presentable format (POINT FORM is best)

Show your Instructor your progress and ask for suggestions

Word process the handout, check for misteaks and hand in!

Conclusion

You are done when you have completed and handed in a high quality, professional handout on your machine/process/future-technology.

Reflection

What did you learn about communication?

How did you enjoy working with your partner?

What difficulties did you encounter?

What was the most effective method to convey your information?

There will be a SAFETY QUIZ following these units, on which you much achieve at least 80% to pass.

Students will make full-sentence corrections for any question they got wrong. Students achieving less than 80% will need to write their corrections in a full sentence and re-write the quiz until they do achieve at least 80%. It is in your best interest to study the materials before hand.

ASSIGNMENT – TOOL BOX

You must determine what tools your kit will consist of, and how much you wish to spend on each tool.

Level 1: Hand tools only (do not include consumables, like oil or rags)

Level 2: Power tools only (do not include consumables, or drill bits or impact sockets)

Level 3: Precision Measurement tools

Level 4: Lathe (D1-4 chuck) and/or Milling Machine (R8 Collet) tooling (assuming you have a basic, complete, machine)

WHAT I’M LOOKING FOR:

You may not be OVER $1000

You may not be less than $995

You may use Canadian or American dollars only. Do NOT include taxes or shipping.

You must source a REAL store, with NEW tools, not Castanet or eBay or the like.

You will create a TABLE using Microsoft WORD, set up with FOUR columns, like this:

You can TOTAL the #Pieces and Price columns easy:

Click in an empty cell at the bottom of the column.

Go to [TABLE TOOLS] -> [LAYOUT] -> “=SUM(ABOVE)”

Watch the person beside you use their calculator, and start laughing loudly at them. Point out that this is in both BOLD, and COLOUR

MEASUREMENT

Woodworker Level: Fractions

LESSON

The basic measurement you will need to work with can be done with simple a ruler or a tape measure. For many projects, whether wood or metal, this is fine.

While you may have learned to measure in Metric, once the US get with the freaking program of the entire freaking Globe, we’re still stuck with measuring in Imperial (feet and inches, and lovely fractions). We’ll try to make it easier for you:

If I bake a blueberry pie, and cut it into two pieces and gave you one piece, you will have received 1 of 2 pieces.  1 out of 2.  If you scored 1 out of 2 on a quiz, it would look like: 1/2.

A smart cookie would also know that scoring 1 out of 2 on a quiz is only 50%.  Half a dollar is 50 cents, or 0.50 of a dollar.

You know all that stuff they taught you in math? Yeah – this is where you use it.  Hope you were paying attention.

ASSIGNMENT

Using the lesson images above as a reference, CLICK HERE to print the worksheet for Imperial Fractional Measurement.

I don’t usually go much smaller than sixteenths when using a ruler.  If I need to be more precise, I use something better, something easier:

TIME MANAGEMENT

The reality:

• • Each class has 160 minutes.
  • With 26 students, each one of you gets 6.15 minutes of my time.
  • If someone needs 12.30 minutes of my time, somebody else gets NO help at all. That somebody might be YOU!

I provide LOTS of Project Booklets and Setup Posters and Hand Outs to help you succeed. USE THEM. It’s like another “me” in the room to help you (only less annoying).

I DO NOT HAVE ENOUGH TIME IN THE CLASS TO DEMONSTRATE EVERY STEP OF EVERY PROJECT TO EVERY STUDENT INDIVIDUALLY.

LEARN TO LEARN
BE RESOURCEFUL
FIGURE THINGS OUT

Don’t be afraid to ask for help – but do YOUR part to help yourself too!

GIVE ME YOUR EFFORT
I WILL GIVE YOU MY HELP.

Bad: “Can you set it up for me?” (Waste of time; no effort on your part!)

Good: “I think this is set up right, can you check it?” (Efficient Use of Time!)

Worst I’ve Been Given: “I learn best if you do it ALL for me.” (Seriously?)

READ THE PLANS.

DO NOT copy your friends. Most of your friends do not read the plans.

Number of Grade 8’s that do not read the plans = 100%
Number of Grade 9’s that do not read the plans = 90%
Destroying your project you copied off your illiterate friend = Priceless.

BASIC LATHE OPERATIONS

WORKSHEET (Updated 2024)

to go with POWERPOINT

PRECISION MEASUREMENT

Metalworker Level: Thousandths

Precisely fitting parts must be precisely made.

The difference between “not fitting,” “fitting” and “way too lose,” can be as little as the thickness of your hair!

You cannot measure this wear with a ruler, you must use more precise tools such as a Micrometer, and a Vernier Caliper, or Dial Caliper.

How to Read Imperial Micrometers

How to Read a Vernier Caliper

How to Read a Dial Caliper

ASSIGNMENTS

WORKSHEET – Micrometers

WORKSHEET – Vernier Calipers

WORKSHEET – Dial Calipers

Dial Indicators, Outside Micrometers, Dial Calipers, Telescoping Gauge

Inside Micrometer Set (Starrett)

THREAD CUTTING

LESSON

You will likely build a project that is assembled with threaded fasteners.

While anything could be assembled with nuts and bolts, sometimes it is super handy to have bolts that thread into the part itself. Like when you can’t actually get to the back side of the assembly, for instance.

The tool we need is a Tap & Die Set. These are commonly available in Metric and in Imperial (SAE). Threads cut inside a hole are done with a TAP, whilst threads cut on the outside of round stock are done with a DIE.

INTERNAL THREADS

In order for the TAP to work, the CORRECT SIZE hole must be drilled. If the hole is too big, the threads will be really loose; if the hole is too small, the tap may not cut, or it may jam and break off. Then you are screwed.

To make sure you drill the right size (and they are SPECIFIC), you need to have a TAP-DRILL CHART (<<< Click to print a copy)

Handy Tips:

• • Make sure the cutter starts straight – if the tap isn’t inline with the hole, you may break the tap (or have crooked threads).
    • Breaking the tap off in your project is a whole world of hurt!
  • Only turn the tap and handle about half a turn (OR LESS) each time, and back it off a quarter turn to break the metal chips off. This avoids over-loading the cutter. TURN LESS, THE SMALLER THE THREADS ARE!
    • Breaking the tap off in your project is a whole world of hurt!
  • Use a high-sulfur oil. I use “Sulflo” which is a special thread-cutting oil (Red Cans in the shop)
  • Protect the cutters: dropping, banging, or striking – they can break very easily.

EXTERNAL THREADS

In order for the DIE to work, the metal diameter must be EXACT. If it is too large, the die may not cut at all; if the diameter is too small, the threads will be really loose. The material diameter MUST be that of the fastener diameter.  A 3/8″ thread can be cut in 3/8″ diameter metal.

The same handy tips apply for dies.

A NOTE ABOUT THREADS:

If you don’t have the RIGHT thread, you have the WRONG thread.

Any thread other than THE RIGHT THREAD, is THE WRONG THREAD.

IMPERIAL (SAE) THREADS

• • COARSE (Unified National Coarse – UNC)
    • Has LESS threads per inch (TPI)
    • A 1/2″x13 thread is 1/2″ diameter, with 13 threads per inch.
  • FINE (Unified National Fine – UNF)
    • Has MORE threads per inch (TPI)
    • A 1/2″x20 thread is 1/2″ diameter, with 20 threads per inch.
    • UNF thread is STRONGER than UNC thread, if you can believe it!
      • There are MORE threads per inch
      • The threads are shallower – so there is more metal left in the fastener.

METRIC THREADS

• • Distance between the threads (in mm)
    • A 12×1.25 thread is 12mm diameter, with 1.25mm between each thread.
    • A 12×1.50 will not interchange – 1.50mm between threads.
    • A 12×1.75 is a very coarse thread – 1.75mm between threads.

THREAD LAW:

• • Threads are unique to themselves
  • It is either THE RIGHT THREAD, or it’s THE WRONG THREAD
  • They do not interchange
  • They cannot interchange
  • “Making them fit” by brute force and ignorance ruins them

ASSIGNMENT

POWER POINT for WORKSHEET. 

You want the FIRST COLUMN of drill sizes (the second column is for -rolled- threads, we want -cut- threads).

FABRICATION TIPS

Cardboard Patterns

Cardboard is WAY cheaper, and WAY faster to mock something up to see that it fits, than going straight to metal.

Once you KNOW the cardboard shape will work, THEN you have a pattern to work it out of metal. Flip the pattern over for a mirrored part!

If you can’t make it out of cardboard, you won’t be able to make it out of metal.

Shock mounts for a project car I built (cardboard, steel, and welded):

Suspension Arm tube lengths and angles:

Suspension 4-link bar mounts:

Frame-to-Unibody Connectors:

Transmission Tunnel:

Inner Fenders: