Wrought Iron Design Project

I just put together this wrought iron design project for my metal 10 program. The package is compliant to the Australian Design and Technology curriculum, but it would work for anyone teaching metal work. In order to produce projects with this booklet you will need some sort of bending tool. Currently I am using a Metalcraft setup, but I have done similar projects with Diacro machines. The project introduces wrought iron work as well as the basic design process. I am planning on giving this booklet to my students this week while I am away on our schools year 7 camp. It will keep the students busy with metal design while I have a non-tech substitute covering my class.

google docs link

How to Forge a Knot Ring

Zachary Brian Yarost from Walled Lake Central High School in Michigan put together a great tutorial on how to make a knot ring. The tutorial is very thorough and easy for students to understand. I foresee students making some beautiful rings.

Thank you Zachary for all your hard work!

imgur picture tutorial  
PDF - Tutorial
Reddit Comments -> have a question? check the Reddit comments first 

Tapering Jig

The Tapered Leg Jig is a great way to add style to any woodworking project. Simple and quick, every shop should have one

Tapered Leg Jig

Bike Rack

The adjustable Bike Rack is a cool weld and fab project and will mike life easyer for people with multiple bikes.

Bike Rack

Making Sumo Wheels (Simple lathe operation)

You can not have a sumo bot with out wheels. This tutorial goes through the basic steps of building sumo bot wheels on a lathe. by no means is this the only way to do it, but with my students it is the most popular.  I like this method because it introduces the junior students to lathe and allows them to work on a very forgiving material. Stay tuned, there will be more sumo bot stuff to come.


The link (google docs)

Building a Sumo Bot Body

This is the third instalment of  the Sumo bot tutorials. This tutorial goes through the fabrication process for building the sumo bot body out of sheet metal. The example bot built is from the Inventor design tutorial posted a few weeks back. There are three more tutorials in this series to come.

Building the bot (link)

Shop Stool

This is a very simple project that introduces students to proper hand tool usage as well as jig assembly / mass production, welding and grinding. The finished product will make an excellent addition to any shop.


Link

Stool

Dog Tags

The Military Dog Tags are a quick and easy beginner project for the metal shop that
teaches, layout, marking, filing, sanding, and letter stamping.

Link:

Dog Tags

Balancing Man

The Balancing Man is a great hand tools based metalworking project. This project introduces the basics of metal layout and hand tool usage. How you build the project and what types of metal you use can be changed, so feel free to experiment. The plans you see here are just basic guidelines on how to make this project. However it is possible to go more in depth and talk about the physics behind the project. The Balancing man is a low cost project that makes a great gift and is fun to play with.


Link:

Balancing Man



pdf drawing

Metal DVD Ends

Anyone that has a collection of Books, CD’s DVD’s or Video Games, knows that unless
you have the right amount sitting on the shelf, the ones on the end always fall over. To
solve this problem we have the “DVD Ends” these small end plates come in handy when
trying to organize your media.
This project is a blending of the Plasma cutter and the arc welder, and is very quick to do
with both Junior and advanced students.

Link:

DVD ends

Here are three popular metal work project sent in by one of the Surrey shop teachers who shall remain anonymous. Three great projects, a small machinist hammer, a Oxy-Ace cutting table and a hose holder. The hammer would take a student a few weeks, same with the cutting table. The hose holder a couple of days.

Hammer

Cutting Table

Hose holder

Simple Drill Press Vice

I love buying new tools. There is just one problem, they always end up costing me money. So i decided to make all of my own tools instead of giving my money to the man.

This vice is a great project for senior or junior students. It was designed by my wife and myself. I drew it up in inventor and have been making it with my students for a year now. It is pretty simple. students will be using welding equipment, hacksaw, drill press and the lathe to make the vice. All of the operations are pretty simple.

Sorry that there are no play by play instructions for this one, but there comes a time where students have to figure things out on their own, with a fare bit of help from yours truly.

The link:

Drill Press Vice

DIY Hacksaw

This is by far one of my favourite projects. It is very cheap to build, does not take too long and students have a working tool that they can use for the rest of their lives. to make this you need some kind of welding equipment, a hacksaw, and a drill. A ruler wouldn't hurt ether.

Link:

Hack Saw

Metal Trivet

This is a very simple metal work project. It is a very good introduction to a course, or a great before Christmas/mothers day project. you van use wood or tile for the top. i have seen another teacher fill it with tile grout and then set small scrapes of stain glass in to it. Looked great.


Link

Trivet

Soft Face Hammer

This is a nice introduction to foundry and lathe work. It introduces simple concepts in foundry, lathe work and lathe based milling. It will take a junior student around 7 days to complete and makes a nice addition to any tool box.

This project is broken in to three parts. First is the student work book which describes the process for making the hammer. the second is how to make the split pattern used to make the casting pattern. The third explains how to make a foundry flask.

Student Work Book

Split Pattern Making

Flask Making

Metal Folding Shovel

This is a very handy shovel it folds up to 8” and will fit in a back pack. It is perfect for digging a car out of the snow or for bringing in your bag on a mountain bike ride. IT takes Grade 9 students about 3 weeks to complete.


Link:

The Folding Shovel

Metal Safe from scratch

The safe is a project that students enjoy manufacturingand learn a lot during the process. This particular Safe can be used to cover most of the Metal fabrication 11Prior Learning Outcomes (PLOs) in British Columbia.This project features machining on the lathe, mill andCNC, welding and fabricating, sheet metal and foundry.


see link:
https://docs.google.com/viewer?a=v&pid=explorer&chrome=true&srcid=0B4G1hbUR7lo-ZjIzZTkxZjEtNmY4Mi00MmE2LWExNTItODcyOWJhNDA3NTAz&hl=en&authkey=CL7qn80P