CHAPTER 6 © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT for SALE OR DISTRIBUTION NOT for SALE OR DISTRIBUTION

© Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION CHAPTER 6 © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

056754_CH06_p140-163.indd 140 4/4/14 6:08 PM © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Applying Basic © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning,6 LLC HandNOT Skills FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

Primary Learning Objectives © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALEAfter reading OR DISTRIBUTIONthis chapter, you will be able to: NOT FOR SALE OR DISTRIBUTION 1. Perform marking-off/marking-out exercises. (pp. 145–146) 2. Perform grinding exercises. (pp. 146–147) 3. Perform drilling exercises. (pp. 148–149) 4. Perform cutting ©exercises. Jones (pp. & 148–149)Bartlett Learning, LLC © Jones & Bartlett Learning, LLC 5. Perform filing exercises. (pp. 150–151) 6. Perform internalNOT and external FOR threadingSALE OR exercises. DISTRIBUTION (pp. 151–153) NOT FOR SALE OR DISTRIBUTION

©Knowledge Jones & Bartlett Objectives Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION After reading this chapter, you will be able to: 1. List and describe basic marking and measuring tools. (pp. 142–145) 2. Use various tools and workshop equipment. (pp. 145–153) © Jones & Bartlett 3. Make a Learning,puller. (pp. 154–160) LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Skills Objectives

After reading this chapter,© Jones you will & be Bartlett able to: Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION 1. Mark off/mark out material. (p. 146) Procedure 6-1 2. Set up, adjust and use a bench grinder. (p.146) Procedure 6-2 3. Sharpen and face tools. (pp. 147–148) Procedure 6-3 4. Set up, adjust and operate a drill. (p. 149) Procedure 6-4 5.© SetJones up, adjust & Bartlettand use a hacksaw.Learning, (p. 149) LLC Procedure 6-5 © Jones & Bartlett Learning, LLC 6.NOT Set up, FOR adjust SALE and use OR a file. DISTRIBUTION (p. 151) Procedure 6-6 NOT FOR SALE OR DISTRIBUTION 7. Set up, adjust and use dies and taps. (p. 153) Procedure 6-7 8. Make a puller. (pp. 154–160) Procedure 6-8

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types of inside calipers consist of the fixed-joint caliper © Jones & Bartlett Introduction Learning, LLC © Jones & Bartlett Learning, LLC and the spring-joint caliper. The spring-joint inside cali- NOT FORDuring SALE the OR course DISTRIBUTION of any day within the workshop envi-NOTper FOR is made SALE up ofOR two DISTRIBUTION legs, a circular spring, a pivot pin ronment, technicians will handle a variety of different and an adjustment device. tools to complete the work tasks. For all tools, the work- Spring jointed-type calipers are provided with an shop will supply some, and others will be part of the adjusting screw, which moves the legs against spring technician’s everyday ©tool Jones chest. & Bartlett Learning, LLCtension. The firm joint has© twoJones legs &fastened Bartlett together Learning, LLC Regardless of whoNOT owns FORwhat, SALEit is the OR technician’s DISTRIBUTION with either a nut or some NOTother anchoringFOR SALE device. OR AllDISTRIBUTION responsibility to: the adjustments are by hand. The spring joint type is the better of the two as it is much easier to adjust, thus ■ Select the correct tools to complete the task. giving it a higher degree of accuracy. The sizes of the ■ Use the tools in a safe manner and to manufacturer’s calipers are determined by the lengths of their legs. They © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC recommendations. are measured from the center of the joint to the bottom ■ NOTMaintain FOR these SALE tools ORto a highDISTRIBUTION standard. NOT FOR SALE OR DISTRIBUTION ■ Clean and store the tools in their correct and proper places.

© Jones & TheBartlett tools andLearning, equipment LLC can be divided into three© Jones & Bartlett Learning, LLC NOT FORmajor SALE categories OR DISTRIBUTION that allow them to be identified easily.NOT FOR SALE OR DISTRIBUTION The groups are: ■ Hand tools: general and manufacturer’s special tools ■ Measuring equipment© Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC ■ Workshop equipmentNOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

Basic Marking and Measuring© Jones & Bartlett Tools Learning, LLC © Jones & Bartlett Learning, LLC MeasuringNOT toolsFOR are SALE precise OR instruments DISTRIBUTION and must be han- NOT FOR SALE OR DISTRIBUTION dled with care. These measuring tools must be cleaned, inspected and stored in such a matter as not to allow Figure 6-1 A typical inside caliper. them to get damaged. Some precision measuring instru- © Jones &ments, Bartlett such Learning,as micrometers, LLC vernier calipers and dial© Jones & Bartlett Learning, LLC NOT FORgauges, SALE may OR require DISTRIBUTION calibration by a suitably qualifiedNOT FOR SALE OR DISTRIBUTION person. When storing these tools for a period of time, they should be cleaned, inspected and given a protective coating such as a light lubricant to minimize the chances of rust forming. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC Calipers NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Calipers are used for transferring measurements or dimensions between the surface faces of a component to reduce sighting errors or mistakes. Calipers basi- cally© come Jones in two & Bartlettformats: inside Learning, calipers LLC and outside © Jones & Bartlett Learning, LLC calipers.NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Inside Caliper An inside caliper is primarily used to measure the internal Figure 6-2 A typical jenny caliper. © Jones &dimensions Bartlett ofLearning, a component LLC Figure 6-1 . The common© Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

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of the legs; the most common caliper sizes are 3 inch, © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC 4 inch and 6 inch (75 mm, 100 mm and 150 mm). NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Another form of inside caliper is the jenny caliper Figure 6-2 . They are used to scribe lines that are parallel to an edge or to determine the center of circles when boring. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC Outside Caliper NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION This type of caliper and its construction are the same as the inside caliper except the legs are facing inward. Outside calipers are utilized for taking outside © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

Figure 6-5 Scribers are sharply pointed marking tools used to make lines on metal to mark cutting or drilling points. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

measurements, such as obtaining the diameter of a pipe © Jones & Bartlett Learning, LLCFigure 6-3 . © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTIONDividing Compass NOT FOR SALE OR DISTRIBUTION A dividing compass is used for drawing circles and curves on metal. Both legs of the compass have sharpened points and the radius can be set by utilizing the adjustable Figure© Jones 6-3 A &typical Bartlett set of outside Learning, calipers. LLC © Jones & Bartlett Learning, LLC set screw Figure 6-4 . NOT FOR SALE OR DISTRIBUTION Before usingNOT the FOR dividing SALE compass, OR DISTRIBUTION a small pilot mark is stamped on the metal to allow one leg to be held in its relative position while the other leg scribes a mark onto metal as it is rotated. © Jones & Bartlett Learning, LLC © JonesScriber & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Also known as an engineer’s scriber, this tool is a sharp, pointed marking tool and is used for drawing lines on metal Figure 6-5 . Normally, it has one straight pointed end, and the other end is bent at a 90-degree angle and © Jones & Bartlett Learning, LLCalso has a sharpened point on© Jonesit. To ensure & Bartlett that the toolLearning, LLC NOT FOR SALE OR DISTRIBUTIONcan be correctly gripped, theNOT center FOR portion SALE is knurled. OR DISTRIBUTION This knurling allows the technician to firmly grip the scriber when marking the metal surface.

© Jones & Bartlett Learning, LLC Retractable© Jones Steel & BartlettTapes Learning, LLC NOT FOR SALE OR DISTRIBUTION One of the NOTmost valuable FOR SALE and versatile OR DISTRIBUTION measuring instruments in the motorcycle tool kit is the retractable steel tape measure Figure 6-6 . Measuring tapes can range in Figure 6-4 A typical divider compass. size from 3 feet to more than 100 feet (1 meter to more © Jones & Bartlett Learning, LLC © Jonesthan 30 & meters).Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

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Figure 6-6 Retractable tape measure being used to Figure 6-7 A steel ruler being used to measure scriber measure a component. marks on a piece of metal that was drilled. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Flat Steel Ruler/Straight Edge A flat steel ruler/straight edge is used when absolute accuracy is not a priority Figure© Jones 6-7 . It& is Bartlett reasonably Learning, accurate LLC © Jones & Bartlett Learning, LLC for measuring smallerNOT jobs. FOR It can SALE also double OR DISTRIBUTIONup as a NOT FOR SALE OR DISTRIBUTION small straight edge when checking a surface for flatness. Steel Squares Steel© squares Jones are & used Bartlett for checking Learning, the angles LLC when long © Jones & Bartlett Learning, LLC metalNOT sections FOR are SALEat right angles.OR DISTRIBUTION They have graduations NOT FOR SALE OR DISTRIBUTION in either imperial or metric values Figure 6-8 . Engineer’s Square Sets Try-Square © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC The try-square is used for squaring lines across a metal plate. NOT FOR SALE OR DISTRIBUTION NOT FORFigure SALE 6-8 SteelOR squares DISTRIBUTION come in various sizes, depending It has many uses in the workshop, such as marking ends on the measuring to be done. of bars and checking the 90-degree angles of components. Combination Square A combination square© is Jonesa tool used & forBartlett multiple Learning, purposes LLC■ Determining flatness:© When Jones working & Bartlett with wood, Learning, LLC in metalworking. It is composedNOT FOR of aSALE ruled blade OR DISTRIBUTIONand one the first step is to designateNOT aFOR reference SALE surface OR on DISTRIBUTION a or more interchangeable heads that may be affixed to it. board, which is known as the face side. The rest of The most common head is the standard or square head, the workpiece is measured from the face side, with which is used to lay out or check right- and 45-degree the next surface being the face edge. angles.© TheJones combination & Bartlett set combines Learning, the featuresLLC of the ■ Measuring© Jones the center & Bartlett of a circular Learning, bar or LLC dowel 45-degreeNOT square,FOR SALE center ORsquare, DISTRIBUTION protractor, try-square ■ SettingNOT and FORmeasuring SALE angles OR: TheDISTRIBUTION protractor head and mitre square. Combination square uses include: allows angles to be set and measured between the ■ Measuring angles: A combination square can base and ruler. reliably measure 90-degree and 45-degree angles. ■ Approximating level surfaces: A rudimentary spirit © Jones & BartlettThe 45-degree Learning, angle LLC is commonly used to create© Jones or& bubble Bartlett level Learning, is incorporated LLC in the protractor and NOT FOR SALEmitre OR joints. DISTRIBUTION NOT FORalso SALE the 45-degree OR DISTRIBUTION holder.

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appropriate for the task and that conforms to your local © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC safety regulations and policies. Among other items, this NOT FOR SALE OR DISTRIBUTION NOTmay FOR include: SALE OR DISTRIBUTION ■ Work clothing, such as coveralls and steel-toed footwear © Jones & Bartlett Learning, LLC■ Eye protection, such © as Jones safety glasses& Bartlett and faceLearning, LLC NOT FOR SALE OR DISTRIBUTIONmasks NOT FOR SALE OR DISTRIBUTION ■ Ear protection, such as earmuffs and earplugs ■ Hand protection, such as rubber gloves and barrier cream © Jones & Bartlett Learning, LLC ■ Respiratory© Jones equipment, & Bartlett such Learning, as face masks LLC and NOT FOR SALE OR DISTRIBUTION valvedNOT respirators FOR SALE OR DISTRIBUTION If you are not certain what is appropriate or required, ask your supervisor. Figure 6-9 This combination square has a bubble level incorporated into the design to help take level measurements. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FORSafety SALE OR DISTRIBUTION

■ Measuring depth or transferring dimensions: By ■ Use safety eyewear when using cutting equipment. moving and setting the head, it can be used as a ■ Do not run your fingers down a newly cut material depth gauge or to transfer dimensions. or threads. They have many sharp edges that will © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC ■ Marking the work surface: The included scribe cut your fingers, and small metal particles will start point stored in aNOT drilled FOR hole inSALE the square OR baseDISTRIBUTION can an infection in the cut. NOT FOR SALE OR DISTRIBUTION be used to mark the work surface. ■ Make sure that you understand and observe all legislative and personal safety procedures when The combination set has a blade that is graduated carrying out the procedures included in this chapter. and a head that is used in conjunction with this blade © Jones & Bartlett Learning, LLC If you are© Jones unsure of & what Bartlett these are, Learning, ask your LLC Figure 6-9 . The set can be adapted into a depth gauge. supervisor. The NOT head hasFOR a SALE 45-degree OR angle DISTRIBUTION and incorporates a NOT FOR SALE OR DISTRIBUTION spirit level. Some even have a scriber housed in the unit for convenience. Marking-Off/Marking-Out Exercises © Jones & Bartlett Using Learning, Various LLC Tools and © JonesTo perform & Bartlett the marking-off Learning, exercise LLC (also known as a NOT FOR SALEWorkshop OR DISTRIBUTION Equipment NOTmarking-out FOR SALE exercise OR) DISTRIBUTIONyou’ll need the following tools: ■ Vise The following workshop procedures will guide you in the skills you need to use various tools and workshop ■ Mild steel equipment, including the steps needed to make a puller ■ Scriber © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC from steel. Each procedure will take you through a spe- ■ Machine blue NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION cific step-by-step process to master the use of each tool ■ Measuring instrument (steel rule or vernier calipers) or piece of equipment. ■ Center punch Personal Safety ■ Appropriate file Whenever© Jones you perform & Bartlett a task Learning,in the workshop, LLC you must To mark© off/mark Jones out & Bartlettmaterial, followLearning, the guidelines LLC use personalNOT FOR protective SALE clothing OR DISTRIBUTION and equipment that is in ProcedureNOT 6-1 FOR . SALE OR DISTRIBUTION

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1 Clean up the material by hand filing to make flat, right- © Jones & Bartlett Learning, LLCangle surfaces. © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION 2 Apply a coating of machineNOT blue and FOR let it SALE dry. OR DISTRIBUTION 3 Using a measuring instrument, scribe lines on the steel following the work diagram measurements. For right angle lines, use a square to ensure accuracy © Jones & Bartlett Learning, LLC of scribe© lines. Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION 4 Note that,NOT if measuring FOR SALE with a steel OR rule, DISTRIBUTION you start 3 the measure at least ⁄8 inch (10 mm) from the beginning of the rule.

5 Use the center punch to mark off/mark out any © Jones & Bartlett Learning, LLC © Jonesdrill & holes.Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

PROCEDURE 6-2 Setting Up, Adjusting and Using a © Jones & Bartlett Learning,Bench LLC Grinder © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

1 2 If needed, adjust the tool ⁄8-inch (3.2-mm) gap and 1 the shatter guard ⁄16-inch (1.6 mm) gap between the wheel. The tool rest should be slightly below the © Jones & Bartlett Learning, LLC © Jonescenter & Bartlett of the wheel. Learning, To adjust the LLC tool rest, locate the NOT FOR SALE OR DISTRIBUTION NOT FORadjusting SALE bolt OR and loosenDISTRIBUTION it with a box-end wrench. Set the tool rest at the right height and distance from the wheel, and then tighten the adjusting bolt. If you are unsure of how to do this, ask your supervisor.

© Jones & Bartlett Learning, LLC 3 Connect the grinder to the© power Jones supply. & BartlettAdjust your Learning, LLC NOT FOR SALE OR DISTRIBUTIONface protector, stand to theNOT side of FOR the wheel, SALE and OR DISTRIBUTION switch the grinder on.

4 After the grinder is fully up to speed, move to the front of the wheel, hold the part you are going to grind firmly onto the tool rest, and move it slowly and gently © Jones & Bartlett Learning, LLC forward© until Jones it comes & intoBartlett contact Learning,with the wheel. LLC NOT FOR SALE OR DISTRIBUTION The grindingNOT wheel FOR removes SALE the OR metal DISTRIBUTION it contacts. Use 1 Before you start using the bench grinder, inspect the the full face of the grinding wheel to prevent wearing wheels and check to see if the tool rest, safety shield one area of the wheel. and shatter guard are adjusted properly. There should also be water in the pot. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

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To set up, adjust and use a bench grinder, follow the © Jones Performing& Bartlett Learning, Grinding LLC Exercises © Jones & Bartlett Learning, LLC guidelines in Procedure 6-2 . NOT FORWhen SALE grinding OR metal,DISTRIBUTION the metal must not be allowed to over-NOT FOR SALE OR DISTRIBUTION To sharpen and face tools, follow the guidelines in heat because this will adversely affect its hardness. If the metal Procedure 6-3 . becomes too hot and is allowed to cool slowly, it may become soft. If it is cooled quickly (quenched), it may become brittle. As you grind the metal, stop and dip it regularly into the water © Jones & Bartlett Learning, LLC TECHnICIAn TIP© Jones & Bartlett Learning, LLC pot attached to the baseNOT of the FOR grinder, SALE which OR will DISTRIBUTION prevent NOT FOR SALE OR DISTRIBUTION the metal from getting too hot. Some bench grinders are not Ask your supervisor to demonstrate the differences supplied with a water pot. If this is the case, you will need between grinding wheels for soft and hard materials to have a water can located near the grinder so that you can and wire brush wheels. As the abrasive wheel wears cool the piece you are grinding. Always make sure you wear down, the gap between the wheel and the tool rest personal© Jones protective & equipment Bartlett whenLearning, grinding. LLC will increase.© Jones This creates & Bartlett a dangerous Learning, situation, LLC NOT FOR SALE OR DISTRIBUTION because ifNOT the gap FOR enlarges SALE toward OR the DISTRIBUTION thickness of the metal you are grinding, the metal could be TECHnICIAn TIP pulled into the gap, which could cause the metal to be thrown with much force. Be very careful when When using the grinding wheel, you will occasionally grinding thin metal pieces, as they are more easily © Jones & dipBartlett the part Learning, into the water LLC to keep it cool. This is © Jonesgrabbed & Bartlett by the wheel. Learning, Your mentor LLC will also explain NOT FOR SALEknown asOR quenching DISTRIBUTION. When you have finished, turn off NOT FORand demonstrate SALE OR how DISTRIBUTION to dress a grinding wheel to the power and unplug the grinder. allow accurate grinding.

1 Using the grinding wheel to sharpen a drill bit. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC The bit should be held firmly on the tool rest before NOT FOR SALE OR DISTRIBUTION beginningNOT the grindingFOR SALEprocess. ORWhen DISTRIBUTION grinding, the bit should be higher than the shank when the bit is moved against the grinding wheel.

STEP 1

© Jones & Bartlett Learning, LLC 2 Using a combination rule© toJones measure & Bartlettthe Learning, LLC NOT FOR SALE OR DISTRIBUTIONbit angles. NOT FOR SALE OR DISTRIBUTION After grinding, use a combination rule to measure the bit angles to make sure they are correct.

STEP 2 © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

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© Jones & Bartlett Learning, LLC 3 Dressing the head of a ©flat Jones screwdriver. & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTIONWhen grinding the head ofNOT a flat FORscrewdriver, SALE you ORare DISTRIBUTION grinding the point. The angle of the point should be parallel to the wheel when you lightly press the tip against the wheel. When finished, you need to make sure the tip of the screwdriver is even on both sides. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

4 Dressing a cold chisel. The chisel has two ends that need to be ground: the striking end and the cutting edge. For the striking end © Jones & Bartlett Learning, LLCof the chisel, rest the chisel© at Jones an angle and& Bartlett rotate it Learning, LLC NOT FOR SALE OR DISTRIBUTIONso there is an even edge aroundNOT theFOR chisel SALE and it isn’t OR DISTRIBUTION mushrooming. For the cutting edge, hold it evenly against the grinding wheel and grind a bit at a time before flipping the chisel over and doing the same. The edge, when finished, should be even and sharp. © Jones & Bartlett Learning, LLC Ask your© mentorJones to &demonstrate Bartlett the Learning, correct angles LLC for STEPNOT 4 FOR SALE OR DISTRIBUTION sharpeningNOT before FOR you SALE attempt ORthe grinding DISTRIBUTION process.

© Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FORPerforming SALE OR DISTRIBUTION Drilling Exercises NOTadjustable FOR SALE reamers. OR DISTRIBUTIONReamers allow a small amount of material to be removed from a hole. Knowing how to operate a drill is an essential part of Ask your mentor to demonstrate these other drilling being a motorcycle technician. Drills are used to make, techniques. countersink and counterbore holes in components, and to remove broken studs.© Jones Always & make Bartlett sure youLearning, wear LLCPerforming Cutting ©Exercises Jones & Bartlett Learning, LLC personal protective equipmentNOT FOR when SALE drilling. OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION To set up, adjust and operate a drill, follow the guide- Hacksaws are the main cutting devices used in the work- lines in Procedure 6-4 . shop. The blade of a hacksaw is tensioned in a frame and Drill presses can also be used for counterboring, is used primarily to cut metal. The blades of the hacksaws countersinking and reaming holes. Counterboring is a are rated according to their cutting pitch, which governs technique© Jones that involves & Bartlett drilling Learning, an initial pilotLLC hole to a the types of© metal Jones they & can Bartlett be used Learning, to cut. LLC certainNOT depth, FOR and SALE then using OR a DISTRIBUTION bigger drill bit to enlarge When cuttingNOT withFOR a hacksaw,SALE OR you DISTRIBUTIONshould make start- the hole part-way through the depth of the workpiece. ing notches as guides for the starting action. Like a file, Countersinking produces a conical hole in the work- the main cutting action is away from your body. Hacksaw piece which allows the head of the fastener to sit flush blades can be brittle, so care must be taken when sawing © Jones &with Bartlett or below Learning, the surface LLCof the surrounding material.© Joneswith one & Bartlett to prevent Learning, the blade from LLC fracturing. NOT FOR SALEA reamer OR is DISTRIBUTIONa fluted cutting device that enlarges NOTan FORTo set SALE up, adjust OR and DISTRIBUTION use a hacksaw, follow the guide- existing hole in a piece of metal. There are fixed and lines in Procedure 6-5 .

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© Jones & Bartlett Learning, LLC 4 Fit the drill bit into the chuck© andJones tighten & it. Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION 5 Before turning on the press,NOT make FOR sure you SALE are OR DISTRIBUTION wearing eye protection and any other prescribed personal protection equipment. Turn on the press.

6 Slowly lower the drill toward the starter hole to © Jones & Bartlett Learning, LLC be drilled.© Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION 7 Drill intoNOT the start FOR hole SALE about ¼ OR inch DISTRIBUTION(or a few millimeters) before raising the drill. Use cutting lubricant to reduce friction of the drill bit.

8 Lower the drill again and make the hole deeper. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC 9 Continue this process until the hole is complete. NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION 10 Turn off the drill press. 1 Secure the piece you are going to be working with the appropriate vise. 11 Use a brush to blow off the metal shavings. 2 Choose the correct drill bit. 12 Remove the piece from the clamps. 3 Select the correct© speedJones on the& Bartlettdrill press for Learning, the size LLC © Jones & Bartlett Learning, LLC 13 Remove the drill bit from the chuck. drill you are using.NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

2 Tighten the blade in the frame. Do not overtighten © Jones & Bartlett Learning, LLC © Jonesthe & bladeBartlett because Learning, this may distort LLC the hacksaw frame. NOT FOR SALE OR DISTRIBUTION NOT FORIf the SALE blade isOR too loose,DISTRIBUTION it may bend and jam while you are trying to cut.

3 Correctly position your feet and grip the hacksaw with both hands.

© Jones & Bartlett Learning, LLC 4 Commence cutting by lightly© drawingJones the & hacksaw Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTIONacross the job. Once the cutNOT has commenced, FOR SALE more OR DISTRIBUTION pressure can be applied, but be careful not to apply too much pressure, as the blade may jam in the material.

5 Continue cutting while constantly checking to ensure you are cutting along the marked cutting line. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION 6 When NOTyou get FOR close to SALE the end OR of the DISTRIBUTION cut, reduce the force you are putting into the cutting action, slow 1 Select the correct blade for the material to be cut. down and lightly cut until the final cut is made. In general, fine-tooth blades are used for material 7 When you have finished cutting, release the tension of a thinner diameter and coarser blades are used on the blade so the frame does not become distorted for thick material. © Jones & Bartlett Learning, LLC © Jonesover & Bartlett time. Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

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smoother. On a job, the coarse file is used first to remove © Jones Performing& Bartlett Learning, Filing Exercises LLC © Jones & Bartlett Learning, LLC material quickly; then a smoother file gently removes the NOT FORFiles SALE are handOR DISTRIBUTIONtools designed to remove small amountsNOT last FOR of it SALE and leaves OR a DISTRIBUTION clean finish to the work. of material from the surface of a workpiece. Files come The full list of grades in flat files, from rough to smooth, in a variety of shapes, sizes and coarseness, depending on follows: the material being worked and the size of the job. Files ■ have a pointed tang on© one Jones end that & Bartlett is fitted to Learning, a handle. LLC Rough files have the coarsest© Jones teeth, & Bartlettwith approxi- Learning, LLC mately 20 teeth per inch (8 teeth per centimeter). Files are often sold withoutNOT handles,FOR SALE but they OR should DISTRIBUTION not NOT FOR SALE OR DISTRIBUTION be used until a handle of the right size has been fitted. They are used when a lot of material must be A correctly sized handle will fit snugly, without working removed quickly. They leave a very rough finish loose while in use. Always check the handle before using and will have to be followed by the use of finer files the file. If the handle is loose, give it a sharp rap to tighten to produce a smooth final finish. it up,© or Jones if it is the & threaded Bartlett type, Learning, screw it on LLC tighter. If it ■ Coarse© Jones bastard & files Bartlett are still Learning, a coarse file, LLC with fails toNOT fit snugly,FOR SALEyou must OR use DISTRIBUTION a different-sized handle. approximatelyNOT FOR 30 teethSALE per OR inch DISTRIBUTION (12 teeth per centimeter), but they are not as coarse as the rough file. They are also used to rough out or remove material TECHnICIAn TIP quickly from the job. © Jones & Bartlett Learning, LLC © Jones■ Second-cut& Bartlett filesLearning, have approximately LLC 40 teeth Hands should always be kept away from the surface per inch (16 teeth per centimeter) and provide a NOT FOR SALEof the file OR and DISTRIBUTION the metal that is being worked on. Filing NOT FOR SALE OR DISTRIBUTION smoother finish than the rough or coarse bastard can produce small slivers of metal that can be difficult to remove from a finger or hand. Clean hands will help file. They are good all-round intermediary files and avoid slipping and will lessen the corrosion caused by leave a reasonably smooth finish. acids and moisture from© Jones the skin. & Bartlett Learning, LLC■ Smooth files have approximately© Jones &60 Bartlettteeth per inch Learning, LLC NOT FOR SALE OR DISTRIBUTION(24 teeth per centimeter)NOT and FOR are SALEa finishing OR DISTRIBUTIONfile used to provide a smooth final finish. What makes one file different from another is not just ■ Dead-smooth files have 100 teeth per inch or more the shape but also how much material it is designed to (40 teeth per centimeter) and are used where a very remove with each stroke. The teeth on the file deter- fine finish is required. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC mine how much material will be removed Figure 6-10 . Some flat files are available with one smooth edge, called NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Because the teeth face one direction only, the file cuts in one safe edge files. They allow filing up to an edge without direction only. Dragging the file backward over the surface damaging it. Flat files are fine on straightforward jobs, but of the metal only dulls the teeth and wears them out quickly. files must be able to work in some awkward spots as well. Teeth on a coarse-grade file are longer, with a greater A warding file is thinner than other files and comes to a © Jones &space Bartlett between Learning, them. A coarse-grade LLC file working on© a Jonespoint; &it isBartlett used for working Learning, in narrow LLC slots Figure 6-11a . NOT FORpiece SALE of mild OR steel DISTRIBUTION will remove a lot of material with eachNOT FOR SALE OR DISTRIBUTION stroke, but it leaves a rough finish. A smooth-grade file has shorter teeth cut more closely together. It removes much less material on each stroke, and the finish is much © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION ANOT FOR SALE OR DISTRIBUTION

B © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION C

Figure 6-11 A. Warding file. B. Square file. © Jones & BartlettFigure 6-10 Learning, The teeth on LLC a file. © JonesC. Triangular& Bartlett file. Learning, LLC Description: NOT FOR SALE OR DISTRIBUTIONThe teeth on a file. NOT FOR SALE OR DISTRIBUTION

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A square file has teeth on all four sides, so you can use it © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC in a square or rectangular hole Figure 6-11b . A square NOT FORfile SALE can makeOR theDISTRIBUTION right shape for a squared metal key NOTto FOR SALE OR DISTRIBUTION fit in a slot. A triangular file has three sides Figure 6-11c . A Because it is triangular, it can get into internal corners. It is able to cut right into a corner without removing mate- B rial from the sides. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC Curved files are eitherNOT half-round FOR orSALE round. OR A half-round DISTRIBUTION NOT FOR SALE OR DISTRIBUTION file has a shallow convex surface that can file in a concave C hollow or in an acute internal corner Figure 6-12a . The fully round file, sometimes called arat-tail file, can make Figure 6-12 A. Curved file. B. Thread file. holes bigger. It can also file inside a concave surface with © Jones & Bartlett Learning, LLC C. File card.© Jones & Bartlett Learning, LLC a tight radius. TheNOT thread FOR file SALEcleans cloggedOR DISTRIBUTION or distorted threads on NOT FOR SALE OR DISTRIBUTION bolts and studs Figure 6-12b . Thread files come in either standard or metric configurations, so make sure you use To set up, adjust and use a file, follow the guidelines the correct file. Each file has eight different surfaces that in Procedure 6-6 . © Jones &match Bartlett different Learning, thread dimensions, LLC so the right face must© JonesTaps & and Bartlett Dies Learning, LLC NOT FORbe SALE used. OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Files should be cleaned after each use. If they are Taps cut threads inside holes or nuts Figure 6-13a . clogged, they can be cleaned by using a file card, or file They normally come in three different types. The first brush Figure 6-12c . This tool has short steel bristles is known as a taper tap. It narrows at the tip to give that clean out the small particles that clog the teeth of it a good start in the hole where the thread is to be © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC the file. Rubbing a piece of chalk over the surface of the cut. The diameter of the hole is determined by a tap file prior to filing willNOT make FOR it easier SALE to clean. OR DISTRIBUTIONdrill chart, which can be NOTobtained FOR from SALE engineering OR DISTRIBUTION

1 Select the correct type of file for the work to be © Jones & Bartlett Learning, LLC © Jonesundertaken. & Bartlett Coarse-teeth Learning, files LLCare used to remove NOT FOR SALE OR DISTRIBUTION NOT FORa lot SALE of material OR quickly, DISTRIBUTION whereas finer-teeth files are used to get a fine finish on the job. A number of different files may be used on the one workpiece to complete the task. For example, commence with a coarse file to remove a lot of material, and finish with © Jones & Bartlett Learning, LLCa fine file to get a smooth© finish.Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION 2 Ensure the file handle is securely attached. 3 Commence filing by gripping the file in both hands and make gentle strokes away from your body. Hold the file parallel to the workpiece throughout the stroke. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC 4 At the end of the stroke, lift the file from the NOT FOR SALE OR DISTRIBUTION workpieceNOT and FOR return SALE to the start OR position DISTRIBUTION to file another stroke.

5 Constantly check the workpiece to ensure you are filing to any marked out lines. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

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may be split so that it can be adjusted more tightly onto © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC the work with each pass of the die as the thread is cut NOT FOR SALE OR DISTRIBUTION NOTdeeper FOR SALEand deeper, OR untilDISTRIBUTION the nut fits properly. The die Figure 6-13d A nut is also common in the workshop . B It is hexagonal shaped to fit a wrench, and it is commonly used to clean up threads that are rusty or have © Jones & Bartlett Learning, LLCbeen damaged. © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Performing Internal and External D Threading Exercises Before you commence the procedure, note the follow- © JonesC & Bartlett Learning, LLC ing points:© Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION ■ A die NOTis a metalworking FOR SALE tool OR used DISTRIBUTION to repair or cut new outside threads on fasteners. A tap cuts internal threads on a workpiece. ■ The die is installed in a diestock. It gives the lever- Figure 6-13 A. Taps. B. Tap handle. C. Stock. D. Die nut. © Jones & Bartlett Learning, LLC © Jones age& Bartlettto turn the Learning, die over the LLC new thread. The die- NOT FOR SALE OR DISTRIBUTION NOT FORstock SALE locates OR the DISTRIBUTION die in place using thumbscrews that match indentations in the outer edge of the die. A tap is installed into a tap handle. It has jaws suppliers. This chart shows what hole size has to be to securely hold the square cross-section at the end drilled and what tap© size Jones is needed & Bartlett to cut Learning,the right LLC of the tap. © Jones & Bartlett Learning, LLC thread for any given bolt size. Just remember that if you NOT FOR SALE OR DISTRIBUTION■ The die has a top andNOT a bottom. FOR The SALE bottom OR has DISTRIBUTION are drilling a ¼-in (6-mm) or larger hole, you should tapered threads to guide the thread into the die. use a smaller pilot drill first. Once the properly sized ■ Use a thread-cutting compound with dies and taps. hole has been drilled, the taper tap can tap a thread It will keep the cutting edge sharp, allowing it to right through a piece of steel to enable a bolt to be be used many times. screwed© Jones into it. & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC TheNOT second FOR type SALE of tap OR is an DISTRIBUTION intermediate tap, also ■ WhenNOT cutting FOR a newSALE thread OR onDISTRIBUTION a bolt, stud or known as a plug tap, and the third is a bottoming tap. workpiece, make sure the tap or die is square onto They are used to tap a thread into a hole that does not the workpiece. come out the other side of the material, called a blind ■ When cutting or repairing a thread, once the die hole. A taper tap is used to start the thread in the hole, or tap has started to cut, turn the die or tap about © Jones &and Bartlett then the Learning, intermediate LLC tap is used, followed by ©a Jones a& quarter Bartlett of a turn,Learning, and then LLC back off. Cut another NOT FORbottoming SALE OR tap DISTRIBUTIONto take the thread right to the bottom ofNOT FORquarter SALE of ORthe thread DISTRIBUTION and back off again. Continue the blind hole. until the thread has been cut. This action clears A tap handle Figure 6-13b has a right-angled jaw the cutting teeth of any scrap and gives a better that matches the squared end common to all taps. finish. The jaws are designed© Jonesto hold &the Bartlett tap securely, Learning, and LLC■ Once the thread has been© Jones cut and & theBartlett die or Learning,tap LLC the handles provide NOTthe leverage FOR SALE for the OR operator DISTRIBUTION to removed, clean the newNOT thread FOR with SALE a wire ORbrush. DISTRIBUTION comfortably rotate the tap to cut the thread. To cut a This will remove any sharp edges and any leftover thread in an awkward space, a T-shaped tap handle is scrap from the new thread. very convenient. Its handles are not as long, so it fits ■ Do not use a wrench to tighten the die-locating into tighter spaces; however, it is harder to turn and thumbscrews. to guide© Jones accurately. & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC ToNOT cut a FORbrand-new SALE thread OR DISTRIBUTIONon a blank rod or shaft, To set up,NOT adjust FOR and SALE use dies OR and DISTRIBUTION taps, follow the a die held in a diestock is used Figure 6-13c . The die guidelines in Procedure 6-7 .

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© Jones & Bartlett Learning, LLC 4 Apply a small amount of thread-cutting© Jones &compound Bartlett to Learning, LLC NOT FOR SALE OR DISTRIBUTIONthe exposed, damaged threadsNOT of FOR the bolt SALE or to the OR DISTRIBUTION tap. If the bolt, stud or workpiece is a separate item, hold it upright in a vise. Make sure the vise is equipped with soft jaws so you do not damage the thread any further. Then tighten the vise so that the bolt or © Jones & Bartlett Learning, LLC workpiece© Jones is vertical. & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION 5 Slowly NOTand carefully FOR turn SALE the diestock OR DISTRIBUTION or tap in a clockwise direction. Make sure to keep the pressure vertically above the bolt or workpiece. You will feel the die or tap removing the metal from the bolt or workpiece. Continue to turn the die or tap until you © Jones & Bartlett Learning, LLC © Jonesreach & Bartlett the depth Learning,to which the matching LLC nut or bolt NOT FOR SALE OR DISTRIBUTION NOT FORwill SALE be tightened. OR DISTRIBUTION 6 To remove the die or tap, turn the diestock or tap 1 Determine the thread size by using a thread pitch gauge to confirm the size. This should match the handle counterclockwise up and away from the bolt. thread it will go into. Clean any filings or particles from the cutting threads © Jones & Bartlett Learning, LLCof the die. © Jones & Bartlett Learning, LLC 2 Choose the correct die or tap set for the job. It will be NOT FOR SALE OR DISTRIBUTION7 NOT FOR SALE OR DISTRIBUTION either inch or metric. Use a rag and then a wire brush to clean the compound and metal particles from the thread of the 3 Fit the die to the diestock or the tap to the handle. bolt or workpiece before you remove it from the vice. For dies, use the locating screw on the stock to engage Test the job by using the correct-size nut or bolt and the hole on the die and secure it into place. For taps, tightening it by hand all the way down. If the repair © Jonessecure by &tightening Bartlett the handleLearning, jaws. LLC is sound,© dismantleJones the& Bartlettdie from the Learning, diestock, clean LLC NOT FOR SALE OR DISTRIBUTION them bothNOT and FOR put them SALE away. OR DISTRIBUTION

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drill press can be used. To make the puller, you will need © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC Making a Puller access to the following tools: NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION In this practical exercise, you are going to make a ■ Scriber ■ Files puller from a metal bar and rod. You will be supplied ■ Ruler ■ Hacksaw with all the materials required to make the puller. You ■ Square ■ Drill press and drill bits will need to use various hand tools to make the puller. ■ Vernier calipers ■ Tap and die The procedures for using© Jones the hand & Bartlett tools and Learning, marking LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION off/marking out the puller are contained previously Steps to Follow in this chapter. You should refer to the various procedures for step-by-step instructions on how to perform Plans for the puller are contained in the following pages. marking off/marking out, drilling, cutting, filing and Make sure you have assembled all the tools you need and thread-cutting© Jones activities.& Bartlett Learning, LLC have at hand© allJones the materials & Bartlett required Learning, to make the LLC puller. Note:NOT The FOR measurements SALE OR used DISTRIBUTION in this exercise are The parts of NOTthe puller FOR should SALE be made OR in DISTRIBUTION the following order: metric. However, if you wish to use American standard 1. Mark and cut the 20 3 20 3 90-mm bar. measurements as an alternative, consult your teacher on 2. Mark and cut the two 8 3 20 80-mm bar. how to calculate them based on the figures provided. You’ll find it a useful mathematics exercise. 3. Mark and cut the 6 mm round bar. © Jones & Bartlett Learning, LLC © Jones 4. Mark & Bartlett and cut theLearning, round rod LLC 10 3 90 mm. NOT FORTools SALE Required OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION To make a puller, follow the guidelines in When making the puller, all work should be done by Procedure 6-8 . hand with the exception of drilling holes, for which a Plans for the exercise are shown on the following pages. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

PROCEDURE 6-8 Making a Puller © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION 1 ExamineNOT the plans FOR that SALE follow this OR procedure. DISTRIBUTION Look carefully at each plan and ensure you have the correct material for making the puller.

2 Gather the material for marking off/marking out. © Jones & Bartlett Learning, LLC © Jones3 & Bartlett Learning, LLC Prepare the material for marking off/marking out by NOT FOR SALE OR DISTRIBUTION NOT FORfiling SALE the workpiece OR DISTRIBUTION surfaces to ensure they are flat and square. Always make sure measurements are taken from flat and square surfaces.

4 Mark off/mark out the workpiece using measuring © Jones & Bartlett Learning, LLCtools and a scriber. Use a center© Jones punch &to Bartlettmark the Learning, LLC center of any holes that are required to be drilled. NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION 5 Perform the required cutting activities by filing, hacksawing or drilling. Always ensure you keep to the marked lines when cutting or filing.

© Jones & Bartlett Learning, LLC 6 Perform© the Jones required & thread Bartlett cutting Learning, activities. LLC NOT FOR SALE OR DISTRIBUTION EnsureNOT threads FOR are cut SALE square toOR the DISTRIBUTIONworkpiece.

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© Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION 80mm 6mm 10mm 8mm © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC

NOT FOR SALE OR DISTRIBUTION 8mm NOT FOR SALE OR DISTRIBUTION

© Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION 10mm 8mm © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION 20mm

© Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION A 90mm 90mm © Jones & Bartlett Learning, LLC 10mm © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION B

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C DEE 90mm © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Side

Step 2

Step 3

B/1 © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOTSteps FOR 4/5 SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

B/2

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20mm

90mm © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

Mark out © Jones & Bartlett Learning, LLC 45mm © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION 20mm NOT FOR SALE OR DISTRIBUTION Top

Side © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION 10mm 8mm

10mm © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

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90mm © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

© Jones20mm & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Tool list: Tool list: 1. Hacksaw 1. Hammer 2. Square 2. Center punch 3. Scriber © Jones & Bartlett4. Vernier Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

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8mm 20mm

NOT FOR SALE6mm xOR 70mm DISTRIBUTION NOT90mm FOR SALE OR DISTRIBUTION

Pin = 6mm x 20mm

Rod 10mm x 80mm 8mm x 10mm 10mm © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

20mm

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Step 3 © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

90mm

20mm

Tools: © Jones & Bartlett Learning, LLC ©1. JonesSaw & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT2. Drill FOR SALE OR DISTRIBUTION

20mm © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

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© Jones & BartlettVocabulary Learning, BuilderLLC and Review© Jones Questions & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Vocabulary Builder file A hand tool designed to remove small amounts of material from a workpiece’s surface. calipers A tool that measures either a component’s internal dimensions or a component’s© Jones &outside Bartlett measurements, Learning, LLChacksaw The main cutting device© Jones used &in theBartlett workshop. Learning, LLC such as its diameter. NOT FOR SALE OR DISTRIBUTIONA hacksaw’s blade is tensionedNOT in FOR a frame SALE and isOR used DISTRIBUTION primarily to cut metal. combination square A tool composed of a ruled blade and one or more interchangeable heads that may be affixed quench To quickly cool a metal piece that you are to it; it is used for multiple purposes in metalworking. grinding. die A© metalworkingJones & Bartlett tool for Learning,repairing or LLCcutting new scriber A ©sharp, Jones pointed & Bartlett marking Learning,tool used for LLC draw- outsideNOT threads FOR on SALE fasteners. OR DISTRIBUTION ing lines onNOT metal. FOR Also SALEknown asOR an DISTRIBUTIONengineer’s scriber. dividing compass A hand tool used for drawing circles steel square A tool for checking angles when long metal and curves on metal. sections are at right angles. drill A tool used to make, countersink and counterbore try-square A tool for squaring lines across a metal plate. © Jones &holes Bartlett in components, Learning, and LLCto remove broken studs. © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

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4. Tech A says that a countersunk hole allows you to © Jones Review& Bartlett Questions Learning, LLC © Jones & Bartlett Learning, LLC fit a fastening device snugly against the workpiece NOT FOR 1.SALE Tech AOR says DISTRIBUTION that when using a hacksaw, the cuttingNOT FORsurface. SALE Tech OR B disagrees.DISTRIBUTION Who is correct? or filing motion should be toward you. Tech B says that when using a file, the cutting or filing motion a. Tech A should be away from you. Who is correct? b. Tech B c. Both A and B a. Tech A © Jones & Bartlett Learning, LLCd. Neither A nor B © Jones & Bartlett Learning, LLC b. Tech B NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION c. Both A and B 5. If you need to mark a piece of metal with accurate d. Neither A nor B lines, you would use the edge of a drill bit. a. 2. If you need to create a new thread inside a piece of True b. False metal,© Jones Tech A& says Bartlett you should Learning, use a grinding LLC wheel. © Jones & Bartlett Learning, LLC TechNOT B FORsays you SALE should OR use DISTRIBUTION a tape and die set. Who 6. When NOTusing aFOR grinding SALE wheel, OR Tech DISTRIBUTION A says there is a is correct? danger of flying sparks. Tech B says there is a danger a. Tech A of eye injury. Who is correct? b. Tech B a. Tech A © Jones & Bartlettc. Both ALearning, and B LLC © Jonesb. & Tech Bartlett B Learning, LLC d. Neither A nor B c. Both A and B NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION d. 3. Tech A says screwdrivers can be sharpened on a Neither A nor B grinding wheel. Tech B says chisels and punches can 7. When making a tool from drawings, it is best to be sharpened on a grinding wheel. Who is correct? start by cutting your main components with a a. Tech A © Jones & Bartlett Learning, LLChacksaw. © Jones & Bartlett Learning, LLC b. Tech B NOT FOR SALE OR DISTRIBUTIONa. True NOT FOR SALE OR DISTRIBUTION c. Both A and B b. False d. Neither A nor B

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