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Home , Marking out, Workbench (woodworking)

CHAPTER ONE | SETTING UP YOUR WORKSHOP

WORKBENCH IS THE HEART OF THE WORKSHOP

If you are setting up your workshop, there is no better place to start than with the . A quality workbench is a pleasure to use, but a rickety structure will quickly prove a hindrance every time it is used.

strong, well-designed the purchase of some prefabricated workbench surface is an important workbench is just as important will save a great deal of time decision. It is likely you will end up with as any other in the compared to making your own. Choose a several benches each with a different workshop. model with as heavy a construction as surface suited for a particular task such AA robust bench can support a decent you can afford because it is far better to as , engine strip-down or bench vice and also cope with any force have a strong bench which is never tested work. exerted on the vice. Benches can be free to its limit than a lightweight unit which Metal is a popular choice for general standing or fixed to a wall as many are becomes rickety every time a heavy use, but needs to be at least three placed against walls when setting up the toolbox is placed on it. millimetres thick for light work and a workshop. The advantage of making your own thicker for heavier work. Wall-mounted benches can be built workbench is that it can be tailored to suit Metal is easy to keep clean and ideal for into the shed structure to improve their your needs and the space available in your working on engines and other items that strength by welding supports to uprights. workshop. It can also be sturdily are sensitive to dirt. Spilt oil is easily Free-standing benches are more versatile constructed and often a large amount of cleaned up and an angle iron draining lip and can be placed in the centre of a room recycled materials can be used in its is often added to the bench top edges to for access to all sides, or moved around as construction. avoid mess. needs change. They can be bolted to the Second-hand steel pipe, RHS or angle But oily metal creates a slippery surface floor to improve rigidity and prevent iron makes an excellent building material which can cause problems. Metal bench movement when using the bench vice. for workbenches because it can be welded tops also tend to react badly to Build or buy? into any form desired, providing rigidity hammering creating noise and vibration. and strength without being overly heavy Thick wooden bench tops absorb There are now many options for those if designed correctly. But there are many vibration well and are less slippery when wishing to purchase a prefabricated excellent workbenches constructed coated with oil, but thick, wide workbench and some are more than entirely of timber that have provided planks are becoming increasingly hard to suitable for heavy work. Others are years of service to their owners. purchase cheaply. Any warping or bowing nothing more than lightweight tables and Top choice of the timber will create gaps between the not worth it. planks which will lead to the loss of small If you are setting up a new workshop Whether you buy or build the choice of items through cracks.

4 Handy Workshop Tips & Techniques www.kondiningroup.com.au | www.machineryhouse.com.au CHAPTER TWO | & TECHNIQUES

TIPS FOR BUYING TOOLS

With so many different brands and styles of hand tools on the market today the choice is sometimes daunting when buying a new spanner, or socket set.

hether stored in a toolbox under the bench, a canvas Sockets bag behind the ute seat, or in a large mobile Wtoolbox in the workshop, hand tools are fundamental to fixing things. We’d all like to be able to afford a Sidchrome or Snap-on 2000-piece toolkit and matching roller draw toolbox, but most of us acquire our tools in dribs and drabs as we need them. Sometimes we buy quality and sometimes the lure of a cheaper set of spanners is too great. While there are no hard and fast rules to tool selection there are several tips, which may help anyone looking for that perfect socket set or screwdriver. 2 If you are looking to save money, but There are different drive sizes used with expand your tool collection, there is 1 sockets: ¼ inch, ³⁄8, ½, and ¾ inch are generally nothing wrong with buying Sockets are a good starting point for a common (left to right), but other larger second-hand, provided the tools are in decent tool set. Impact sockets (left) have sizes such as inch and 1½ are used for good condition. There are many options six points and thick, solid walls to stand heavy machinery. The ¼ inch is fine for for finding good second-hand tools at up to the strain of being used with an fiddly work, but a 3/8 drive is more bargain prices such as online auction sites impact . They are also good for handy and can stand up to more and classified advertisements as well as using with rounded-off nuts and bolts, forceful use. Sockets often come in second-hand stores. Even auctions and which may slip when used with a combination ¼ and 3/8 drive sets, or dispersal sales can throw up bargains standard double hexagon (12 point) ¼ and ½ inch sets. A good starting every now and again. socket (right). Choose a quality set of point set for everyday work is the ½ Other tools are so cheap these days you 12-point sockets, which will have thinner inch drive, which can handle a large may as well purchase them new. If you are walls, but are easier to use in tight, amount of force and usually covers sizes buying a tool to use occasionally then it confined spaces. Beware of cheap, from about 12-32mm. For heavy duty also makes sense to purchase a lower cost low-strength sockets such as the 6-point work, ¾ or one inch drive will handle brand rather than an expensive label. socket (centre). large force without failure. www.kondiningroup.com.au | www.machineryhouse.com.au Handy Workshop Tips & Techniques 33 CHAPTER THREE | MEASURING & MARKING

Quality work requires accurate measurement and . While there is a range of tools to help you with this, you also need a thorough understanding of some of the pitfalls and areas where inaccuracy can creep into you work.

MASTER THE ART OF MARKING OUT

he secret to completing a according to the international system of Scribing a line successful task is knowing how units (SI). to mark out and measure a job In engineering, the millimetre is king, accurately. and all units are usually expressed in TWhile there are some very expensive millimetres. The standard unit of precision measuring and marking tools precision is a hundredth of a millimetre, available, there are also cheaper or 0.01mm. alternatives that can provide good results The imperial system was used for many if used correctly. years in Australia before the metric system Most jobs require some form of was introduced and is still the favoured marking or layout before any work measurement system in the USA. The 1 commences. This is where many mistakes standard imperial engineering unit is the A is the first place to start occur, leading to wastage of materials and inch (25.4mm), and precise measurements because it is used to make accurate time. are usually expressed in thousandths of an marks or scratches on metal. While The old adage ‘measure twice, cut once’ inch (0.001" or 1⁄1000 inch). there is nothing wrong with using a holds true because it only takes a second Measurements less than an inch are pencil or marker pen for basic marking to double-check your measurements and often expressed in fractions, for example, out, if you want accuracy better than marks before any cutting commences. ⅜ of an inch is equivalent to 0.375" plus or minus a millimetre a scriber is (3x1000⁄8). Even if you have never needed the tool to use. This scriber has a Metric is the standard to use the imperial system you should straight end for general marking and a Today, the standard system of learn how to make precise imperial bent end for access in restricted measurement is the metric system, with measurements. Many components and spaces. Scribers are sharpened to a the metre being the base or standard unit fasteners are still based on imperial units. fine, sharp point on a bench grinder.

68 Handy Workshop Tips & Techniques www.kondiningroup.com.au | www.machineryhouse.com.au CHAPTER FOUR | FASTENERS & WORKSHOP SUPPLIES

KNOW YOUR Discovering the identity of a mystery thread need not be a guessing game, but a methodical approach, coupled with a little know-how, will THREADS usually solve the puzzle.

ountless hours are wasted National Coarse (ANC). Pipes and fittings TABLE 1: Common thread acronyms each year in workshops around generally have their own specified thread the country trying to match- types, including British Standard Pipe UNC Unified National Coarse up a mystery nut or bolt. For Thread (BSP) and National Pipe Thread Cexample, UNC, BSW, UNF, NPT, ANF (NPT). BSPT (the T means the thread is UNF Unified National Fine or metric – it can really do your head in tapered) is commonly used in all water trying to determine what that thread is. If pipe fittings today. ANC American National Coarse we lived in a perfect world all thread sizes Often a machine’s country of origin would be standardised, but that is not the can provide a clue as to the fastener ANF American National Fine case. Today, many machines and vehicles thread types. For example, machinery use mainly metric threads, or Unified made in will use metric threaded BSP British Standard Pipe National Coarse (UNC) and Unified fasteners, while North American National Fine (UNF). machinery will feature fasteners with NPT National Pipe Thread Other less common threads include UNF or UNC threads. Older British BSW British Standard Whitworth British Standard Whitworth (BSW), machinery will invariably use BSW or British Standard Fine (BSF), American BSF threads, which are a real pain as taps BSF British Standard Fine National Fine (ANF) and American and dies can be difficult to source. www.kondiningroup.com.au | www.machineryhouse.com.au Handy Workshop Tips & Techniques 83 CHAPTER FIVE| STEEL

DRILLING FOR PERFECT HOLES

There is more to drilling a hole in metal that just whacking a bit in a drill and going for it. There are several variables such as speed, feed rate, coolant and that need to be taken into account.

he drill press or pedestal drill is hole in steel with a hand drill will know attachment. a fundamental machine in any how difficult and time consuming it can Clamping odd shaped work or items at metal working shop. be. The drill press has the advantage of a various angles other than 90 degrees can Whether drilling large holes moveable that can be advanced be a bit of an art, but there are a range of Tthrough steel at slow speed, or precisely down into the work under even, accessories available to help. There are drilling accurately spaced holes for downward pressure. also several ways of ‘making do’ without tapping threads the drill press is hard to Spindle speeds are also adjustable via resorting to expensive clamping kits or do without. changing belts on stepped pulleys or gears vices. Even a small, low-cost drill press is on more expensive machines. Low spindle A drill press has other applications than capable of accurate work provided it is set speeds are used for large holes, higher just drilling and makes a perfect centring up and operated with care. Larger speeds for smaller holes. See page 132 tool for starting thread taps. Equipped floor-standing machines can tackle a for recommended drilling feeds and with a thread tapping attachment it can surprising range of work and are available speeds. power-tap threads using the quill feed to at various prices from three pulley models The key to drilling accurate holes is advance the tap into the work. (as used in this article) to geared head, effective and firm clamping of the work. With a notching attachment and metal radial arm units that cost many thousands A heavy drill press vice is an essential cutting hole , the drill press can cut of dollars. accessory for any machine and most notches in a range of sizes and angles for Anyone who has tried to drill a large work can be clamped using this neat, strong joins in round tubing.

126 Handy Workshop Tips & Techniques www.kondiningroup.com.au | www.machineryhouse.com.au CHAPTER SIX | GRINDING, POLISHING & CUTTING

BENCH GRINDERS A BASIC NECESSITY

The bench grinder is capable of more work than simply grinding and can be fitted with a range of accessories for polishing and cleaning metal.

he humble bench grinder is one rates and lead to excessive heat. of the handiest machines you A thorough risk assessment needs to be can have in your workshop and taken before the use of any accessories many workshops feature more because these might not be suitable for Tthan just one. all bench grinders. Some accessories While bench grinders are typically used such as wire brush wheels and polishing for sharpening drill bits or taking the mops require the removal of safety off a cut piece of steel, they are guards. capable of a wide range of tasks when The choice of bench grinder is also fitted with the correct attachments. But important in terms of both safety and like most tools in your workshop bench useability. A 150mm (six inch) bench grinders need care to produce their best grinder might be ideal for sharpening work. A poorly maintained grinder is a drill bits, but overstressed for general safety hazard as well as being difficult to grinding duties. A 200mm (eight inch) use. bench grinder of at least 500 watts is a On even the most basic grinding tasks suitable starting point for most the bench grinder needs to be kept in workshops, with larger workshops easily tip-top shape to produce good results. justifying a more powerful unit with Accurate sharpening of a drill bit is 250mm capacity. impossible on out-of-round, irregular One option is to use both a smaller grinding wheels, which cause vibrations bench grinder for delicate jobs such as and can lead to wheel failure at high sharpening drill bits and polishing and a speed. Clogged wheels also reduce work larger grinder for general grinding duties.

154 Handy Workshop Tips & Techniques www.kondiningroup.com.au | www.machineryhouse.com.au CHAPTER SEVEN | WORKING WITH METAL

WORKING WITH SOLID STEEL SECTIONS Solid steel sections are great to work with, as they bend well, are easy to weld, and can be made into decorative shapes. Once, all metalwork was done by a blacksmith using solid wrought iron, but today mild steel is often worked by cold as well as hot working.

here are two ways of working with solid sections; hot and cold forming. Cold forming, where steel is just bent without any Tapplication of heat, is often preferable as it is quick and easy. But it often requires a great deal of force for heavier sections, and can lead to cracking and weakness around the bend. Hot forming relies on some method of heating, whether it be a furnace, a blacksmith’s or an oxyacetylene torch. It has the advantage of easier working, and the steel can be deformed further, allowing tighter bends, and less 1 chance of cracking. Flat bar can often be bent in the bench vice by clamping firmly, and then striking the Many of the cold forming processes bend with a hammer as the steel is pulled over with the other hand. outlined here can also be performed hot. In fact, many cold forming machines are limited in the size of steel they can handle cold, but can accommodate larger sections if used hot. Structural sections, which are often hollow like pipe and RHS, often require more involved processes to bend to stop the section collapsing or buckling. This is not generally the case with solid sections. Solids are also easy to join by welding, unless they are very thin, as there is 2 ample metal to form a good weld. Hollow The finished bend should have a nice sharp corner, without any cracks along the sections need more work to provide outside. If you attempt to bend too thick a section, it will require considerable force, adequate join area for welding (see page and cracks will form along the outside of the corner. 181 for more information).

176 Handy Workshop Tips & Techniques www.kondiningroup.com.au | www.machineryhouse.com.au CHAPTER EIGHT |WELDING

KNOW THE BASICS FOR GOOD WELDS

In order to form strong, neat welds it is important to understand the processes at play when you strike an arc.

elding is the process of The circuit has a negative and a positive current flow than the wires in the circuit, joining metals with heat, terminal, with the current flowing from so heat and light are generated. and it is as common as the the negative terminal to the positive The same process is used to generate use of metal in our everyday terminal. The flow of electricity is actually heat for welding, except the area of high Wlives. a flow of electrons, which are sub-atomic resistance is the electrical arc between the The heat, commonly generated with an particles carrying a negative charge. electrode and the work. The higher the electric arc or gas flame, needs to be hot The voltage of an electrical flow is a current the more heat is generated. enough to melt the metals being welded. measure of the potential difference The melting process is usually between two points, or between the Putting theory into practice accompanied by a filling process where positive and negative terminals. A welder operates on the same principle additional metal is added to make a strong Current is a measure of the flow rate of as the closed circuit in Figure 1. The joint. voltage, measured in amperes (amps). switch is closed when the electrode tip Welding metal opens up a range of The size of the current flow depends on touches the work (see Figure 2). The fabrication possibilities because welded the electrical pressure (voltage) and the current flows through the arc between the joints are strong, neat and cheap to diameter and length of the wire. electrode tip and the work, creating heat, produce. Without welding the joining of More current can flow through a thick and then flows back to the welder through metal parts would be limited to the use of short wire than a long, skinny one. This the earth cable which is attached to the fasteners such as bolts and rivets. restriction to current flow is called work. As most welding methods use an resistance and is measured in ohms (Ω). The welder also reduces the mains electrical arc to generate heat it is useful Resistance depends not only on the electricity from 240 or 415 volts to a much to have a basic understanding of how diameter and length of a wire but also on safer level. The welder is basically an electricity works during welding. the material it is made of. Metals in adjustable transformer, which boosts general have a low resistance to the flow current by lowering voltage. This high Electric welding basics of electricity (for example, copper is current will create enormous heat when it With any electrical circuit power will only commonly used in electrical wiring flows through an area with a high flow when the circuit is connected to the because it has a low resistance to current resistance. power source in a loop (see Figure 1). This flow). The welding and earth cables both have is called a closed circuit — electricity Heat is generated when current flows a large diameter and can carry a high flows from the power source through a through an area of high resistance. The amount of current with little resistance. switch to the load, in this case a light tungsten filament in the light globe in But when the current has to flow through globe and back to the power source. Figure 1 has a much higher resistance to the welding arc and into the work it meets

204 Handy Workshop Tips & Techniques www.kondiningroup.com.au | www.machineryhouse.com.au CHAPTER NINE |

MASTERING THE METAL LATHE

he metal lathe is a hugely into the work. This is called facing and which travels along the bed and provides versatile capable can be performed on cylindrical or sideways movement of the cutting tool for of a wide range of precision irregular shaped objects. turning operations. It can be quickly operations from turning, facing, The output shaft of the lathe is called moved into position using the carriage Tboring and drilling, to more complex the spindle, which protrudes form the hand wheel, which acts on a geared rack tasks such as thread cutting, turning headstock. The headstock is attached to running the length of the bed. tapers and steel. the lathe bed on the left hand side. Long Most metal lathes are fitted with an The range of tasks a lathe can perform work can be supported between the auto-feed system inside the carriage, is vast and fitted with a range of headstock spindle and the tailstock on the which takes some of the hard labour out accessories — it seems there is almost right hand side, which is able to slide of turning and facing operations. Apart nothing it can’t do. along the bed to cater for work of different from making these tasks easier, auto- In its most basic form a metal lathe is a length. feeds allow very fine, measured rates of machine able to turn cylindrical parts to a Cutting tools are attached to the feed, which improve the accuracy and high degree of accuracy. Work such as a compound slide, which allows fine surface finish on machined parts. shaft can be held between centres or in a adjustment of tool position, and an Metal lathes use either a gearbox or belt and a tool applied along the rotating adjustable angle of travel for taper turning drive and step pulleys to vary the speed of work piece to reduce its diameter. This is and chamfering the ends of shafts. the spindle, allowing the turning of small known as turning and is the most The compound slide is attached to the diameter parts at high speed, or large common work performed in the lathe. cross slide, which travels across the saddle diameter parts at a low speed. Some small Often, parts require an accurate flat to alter the depth of cut when turning and hobby lathes feature an electric variable surface and the lathe is also capable of to advance the tool across the work when speed drive. producing this. Instead of feeding the tool facing. Slow spindle speeds are also useful for along the work it is moved at right angles Both slides are attached to the carriage, thread cutting, another capability of the www.kondiningroup.com.au | www.machineryhouse.com.au Handy Workshop Tips & Techniques 253 CHAPTER TEN | MACHINERY

TABLE TECHNIQUES

he is a simple but between the blade and the hands will violently towards the operator. It is fitted versatile machine and forms result in loss of fingers and severe cuts. behind the blade and holds the cut apart the cornerstone of most But the guard will need to be removed preventing it from closing on the back woodworking shops. occasionally for certain operations half of the blade. Some splitters feature TCapable of a wide range of accurate because it will impede the work, or the pawls, which hold the work down as it is work the table saw is a simple machine, use of accessories such as a mitre sled. slid past the splitter. but must be used correctly to avoid Take extreme care when the guard is As with the blade guard there are serious injury. removed and always replace it when you certain instances where the splitter must In its basic form the table saw features are done. be removed such as cutting a a saw blade mounted on a shaft under the The splitter is the second safety device where the blade doesn’t extend through table surface (see Figure 1). The blade can fitted to the table saw and it is used to the work. Make sure the splitter is refitted be raised or lowered as desired to alter the prevent kickback where the work is because it will save you from injury at depth of cut and tilted sideways to cut at picked up by the blade and flung back some point. an angle other than 90 degrees. A moveable is attached to rails and is used to guide work during cutting operations. The table is fitted with mitre slots, which run parallel to the blade C allowing the use of mitre gauges and D other accessories. E B Play it safe A F Any spinning blade is a potential source of serious injury, but the table saw can maim an operator who does not consider the dangers of kickback when cutting wood to size. G The table saw is fitted with two main H safety features: the blade guard and the I splitter. If you are buying a second-hand machine make sure they are both Figure 1: The table saw included. The purpose of the blade guard is A: Table. B: Blade. C: Blade guard. D: Splitter. E: Mitre slot. F: Fence. G: Blade depth obvious and even momentary contact hand wheel. H: Blade tilt hand wheel. I: On/off switch.

290 Handy Workshop Tips & Techniques www.kondiningroup.com.au | www.machineryhouse.com.au