ASSEMBLE ALUMINUM TOOLBOX

Transcription

1 ASSEMBLE ALUMINUM TOOLBOX INTRODUCTION In this lessn, yu will assemble an aluminum sheet metal tlbx using rivets. Yu will start with a kit that includes pre cut and pre frmed aluminum tlbx panels. This kit als includes the handle, latch, hinge, and a variety f rivets. Finished tlbx measures 16"L X 6"W X 4"H. In this lessn yu will experience: Filing. Hack saw. Deburring edges and hles Drilling hles. Dimpling hles. Clec clamps. Variety f rivet types, including slid Rivet installatin, including squeezing, pulling, and bucking. Remving Rivets. The cmpleted tlbx. In additin t the specific skills mentined abve, the mentr will impart his experience and knwledge f recgnizing prblems t avid, safety cnsideratins, the feel fr using varius tls, hw t recgnize quality wrk, disciplines, and ther big picture cnsideratins. Cmpleted Intrductin 1

2 Preparatin Determine any required Persnal Prtectin Equipment. Inspect tls t ensure wrking cnditin. REQUIRED ITEMS PPE: Safety glasses and glves. Drill: Crdless r air. Drill bits: #30, #40, 12 inch #30 Clecs: #30 and #40 Hle deburring tl. Blue fine tip Sharpie Hacksaw Files fr edge deburing. R Flex 120 grit spindle munted pint Rivet Squeezer (Brrw Rd Beckwith Main Squeeze) Pull rivet tl. Edge rlling tl. One piece rivet test gauge. Masking tape 2

3 PROCESS STEPS Preparatin and Review Unpack the kit, identify parts, and review intended assembly instructins. Ntice writing n aluminum. Ntice the ends have mre hles ne side than the ther. Why? These hles are starter hles. Review the varius rivets. Ptential mistakes and pitfalls. Hinge peratins. This prject will flip the hinge pieces in nnstandard way. This starting kit. Remve blue plastic cating. Remve the plastic. Mark the ends t prtect frm mistakes. D nt use black markers. Black cntains carbn that can harm the aluminum. Use blue. NOTICE: There are extra hles n ne edge. The edge with fur hles is cnsidered the back f the tlbx. Help prtect frm making a mistake by clearly labeling rientatin f the end pieces. Use blue Sharpie. (Nt black.) Cmpleted Preparatin and Review 3

4 Debur edges and rund the crners. Use tw different methds Flat File Wear a glve n yur nn dminate hand. Make sure the file teeth are perpendicular t mvement in rder t cut. Use a flat file alng all edges in at three angles Square t the edge surface. 45 degree t the tp edge; 45 degree t the bttm edge. Deburring Spindle Munt the 120 grit spindle int the drill press. Mving frm left t right (int the rtatin f the spindle) debur all edges at three angles. Parallel t the edge surface. 45 degree t the tp edge; 45 degree t the bttm edge. Ovid creating grves in the spindle by cnstantly mving up and dwn as yu mve the edge acrss the spindle. Sme tight crners and limited access areas can nly be deburred with a small file. Cmpleted Debur edges and rund each crners. 4

5 Reverse the hinge pieces. Remve the hinge pin. Flip ne side. Insert the hinge pin. Rund the end f ne end f the hinge t assist in insertin. Reverse the halves f the hinge pieces. Cmpleted Reverse the hinge pieces. Cut hinge t length. Mark the hinge t cut. Hld hinge in psitin t where the right side f the hinge will be attached t the tlbx. At the left side f the tlbx place a tick mark t where the hinge will be cut. Place the hinge n a table. Using a straight edge, extend the tick mark t a full line. At the ppsite end, mark the lnger hinge part flush with the shrter half. Cut hinge Disassembly the hinge by remving the hinge pin. D nt cut the hinge pin, yet. With a hack saw, cut the hinges halves at the marks. At ne end, yu will need t cut ne f the tw hinge halves s they are the same length. Cmpleted Cut hinge t length. 5

6 Edge rll the ends. Use glve n the hand that is hlding the part. This adds a slight bevel t the edge. Only the tp edge f each end. Rll inward twards the inside f the tlbx. The purpse is t allw these edges t tuck underneath the lid withut interference. Cmpleted Edge rll the ends. Clamp the end panels t the main bdy by using Clecs. Use Size 3 Clecs. (Silver) Insert int every ther hle. Avid center fur hles at bttm edge. Place piece f masking tape ver the bttm fur hles t remind us nt t drill thse hles yet. Cmpleted Clamp end panels 6

7 Match drill the end panels. #30 fr flush rivets Yu may need t mve a few Clecs t access any particular hle when match drilling. Remve tape #40 fr fur pull rivets fr center fur hles alng bttm edge. Cmpleted Match drill end panels. 7

8 Debur hles Detach the end panels by remving the Clecs Debur each hle n bth sides f the end panels AND bth sides f the main bdy. The dgleg hle deburring tl will nt wrk fr inside the tlbx bdy because the handle and dgleg hit the side f the tlbx bdy. Yu will need remve the deburring tip and use yur fingers t turn it in the hle. HINT: Yu can get better leverage n the deburring tip if yu munt the deburring tip nt an extensin rd and turn it by hand. Fr the center fur hles, yu will need t replace the 3/32 tip with a 1/8 tip. Cmpleted Debur hles. 8

9 Dimple hles Use size 3 dimple set. Calibrate the squeezer by testing in ne hle until the rivet is very slightly belw the surface f the aluminum. The rivet will expand upwards very slightly when it is squeezed. D nt dimple the bttm fur hles where the pull rivets will g. WARNING The dimple must defrm the aluminum twards the inside f the tlbx s that the rivet sits flush n the utside. Make sure yu d dimple in the crrect directin! It is imprtant that the rivet squeezer is very square t the surface while squeezing. Cncentrate n nt wiggling r mving the angle f the squeezer while clsing the handles. HINT: This is best dne with tw peple when yu are new t perating the squeezer. The secnd persn can help determine if yu are square t the surface r t assist in psitining the squeezer. HINT: Make sure yu have a clear line f visin with bth eyes t the squeezer. HINT: Mve yur head t a secnd psitin t help determine if the squeezer is square. Cmpleted Dimple hles 9

10 Flush rivet the ends Clamp the end panels t the main bdy by using Clecs. (Silver and Cpper) Change the die set in the squeezer t a flush die set. Insert a #3 flush rivet int a hle. Remve and mve adjacent Clecs as needed. WARNING Make sure the tw aluminum pieces are pressed against each ther withut a gap. Calibrate the squeezer n ne rivet by intentinally under sqeezing and incrementally adjusting the squeezer until the rivet is crrectly squeezed. HINT Make sure yu have psitive pushing pressure n the head f the rivet. This frce will insure the rivet is tightly seated and tends t push the tw aluminum pieces tgether. Use the ne piece rivet gauge t test yur rivet. NOTE: The prper length flush rivet has been selected fr this kit. In ther circumstances, yu may need t purchase the crrect length r trim lnger flush rivets shrter t the size yu need. Cmpleted Flush rivet the ends. 10

11 Pull rivet the bttm fur hles Use #4 (1/8 inch) pull rivets. NOTE: The prper size pull rivet has been selected fr this kit. In ther circumstances, yu may need t purchase the crrect size pull rivet. Pull rivets cannt be trimmed shrter. Pull n the squeezer handle. The stem f the pull rivet may nt snap in ne pull f the handle. Yu may need t get anther bit n the stem and squeeze again. Be carefully nt t change yur angle while taking a new bite r pulling the handles. Cmpleted Pull rivet the ends 11

12 Clamp hinge t bdy Use C clamps t gently secure ne half f the hinge t the backside f the tlbx bdy. Set the clamps t a lse tightness s that the hinge can be nudged easily. Psitin the hinge in its apprximate psitin as fllws. Lps facing up. Tp edge f lp flush with tp edge f tlbx bdy. Centered left and right s there is rughly equal space n the ends. Using a ruler, measure the gap at bth ends f the hinge. Nudge the hinge until the hinge is centered the best yu can. Verify that the tp f all hinge lps are flush with the tp edge f the bdy. Nudge if needed. Tighten the C clamps. Add additinal clamps t the hinge, such as Clec jaw clamps. Lking ahead t a future step, yu shuld leave everyther gap unclamped s we can rivet int the unclamped hles. Big Picture: Lk again. Verify that the hinge did nt mve while yu tightened and added clamps. Lsely clamp the hinge in its apprximate psitin. Use a ruler t accurately center the hinge. Cmpleted Prcess Steps 12

13 Drill hles in bdy fr hinge. T help brace the back side f the bdy frm flexing while drilling have a secnd persn hld a piece f wd behind the hle that is being drilled. Select the 12 inch lng #40 drill and lad it int the crdless drill. The lng drill is required because the crdless drill interferes with the frnt side f the tl bx thus preventing yu frm drilling a straight hle. The lng drill allws the crdless drill t be utside f the tlbx. Drill the first hle int the hinge. Yu can stp when wd chips are visible. Nte: The lng drill bit flexes very easily. D nt push t hard. If flexing des ccur, then use yur fingers t brace the drill bit at the mid pint f the drill bit shank t help keep it frm flexing. Nte: Remember, a prper drilling speed and frward press results in lng curly chips. Yu can best accmplish this by running the drill at a medium r slw speed with mderate frward pressure. N need t Place a Clec int each whle after it is drilled. Mve the wd brace and the drill bit t the next gap t drill the next hle. Repeat until all the gaps are drilled and have a Clec. One at a time, remve a clamp and drill the hle. Insert Clec after drilling. 13

14 Dimple the bdy hinge Remve the hinge by remving all the Clecs. Deburr all the hles in the hinge and the back wall f the tlbx. Dimple the hinge. Dimple the back wall f the tlbx. Attach the hinge nt the bx with Clecs in every ther whle. 14

15 Rivet the bdy hinge. Using 3/32 flat head rivets, squeeze a rivet int each hle in the hinge. Start with every ther whle that have n Clec clamps. Then ne at a time, remve a Clec and squeeze a rivet int that hle. Remember t validate each rivet with the rivet gauge. 15

16 Attach stiffener t frnt inner f bx bdy. Clec the stiffener t the inner side f the bx bdy. Every ther hle. Lad a #30 jbber drill bit int the crdless drill. Drill the hle. Place Clec int new hle. Repeat fr all pen hles. One at a time, remve the Clecs frm the undrilled hles and drill them. Remve stiffener. Debur stiffener. Reattached the stiffener t inner side f the bx bdy. Squeeze 1/8 rund head rivets. 16

17 Rivet Latch t bdy 17

18 Next Next 18

19 Step 4 Perfrmance Standards Review Student applied all required safety precautins. Student crrectly identified all tls listed in the intrductin. Student crrectly explained and demnstrated the applicatin f each tl. Student cleaned the wrk area and prperly stred all tls and equipment. Additinal Cmments: Step 5 Sign Off Student: Mentr: Date: 19