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Metal Shaping and Fastening

Description:

Have you always wanted to work with metal?  Do composites and all the chemicals that go with them worry you?  Do you want to be able to make structures that are not just light, but sturdy and able to take day-to-day abuse?  Are you trying to fix a car, or some other vehicle or trying to build a structure that needs to bear a serious load?  Then this is a course for you.  Learn how to rivet materials together, form sheet into complex shapes that can resist loads and build structures that last and are impervious to the sun and the more resistant to the elements.  We will take our skills and apply them to a real-world project towards the end of the session.

What will you learn from this class? 

·  How to cut, flange, dimple, bend and otherwise shape sheet metal into some basic shapes using basic tools.

·  How to determine the number, type and spacing of rivets before you begin assembly

·  How to drill, de-bur, dimple and countersink holes for riveting, including locating holes in materials under your undrilled sheet.

·  How to pop (aka blind) rivet consistently

·  How to solid rivet consistently

·  How to form structural components out of sheet metal (e.g. angles, gussets)

·  How to create strong structures using differently shaped parts

·  How to stress relieve material and stop drill cracks to prevent them from spreading

·  How to patch cracked materials and surfaces with riveted patches

What will you make in this class?

·  A small frame held together with pop rivets using gussets, square tubing and angle material

·  We will ruin a piece of sheet metal and then patch it

·  We will add to your frame by riveting some angle brackets and then lay a sheet metal surface (like a floor on a vehicle).  We will use various pop and solid rivets

·  We will create a short ‘C’ beam using solid rivets and introduce you to ‘webbing’


What will you need?

You will be provided with a small kit containing:

·  Consumables like sheet metal, pop and solid rivets, tubing and aluminum angles

·  Several 1/8” metal drill bits (you can’t have enough of these)

If you have and would like to bring along the following, feel free to do so, but we will be providing these for your use.

·  Pop rivet gun with 1/8” tip

·  Corded electric drill (cordless drill batteries will fade quickly)

·  Fine metal files

What do you need to know beforehand?

Nothing really.  I am assuming you do not know anything about this stuff.  A lot of the skills you learn here are transferable to other projects and disciplines

What are some of the tools we will use?

·  Rivet guns (pop and solid)

·  Bucking bars

·  Drill press

·  Countersink and Deburing tools

·  Dimples and Dies

·  Flanges

·  Home-made flanging tools (if I make one in time)

·  Cleco tools and clecos

·  Nibblers and shears

·  Snips and shears

·  Bending brake

·  Rivet cutter

What will it cost?

·  The class fee is $40 which includes the consumables

Join or login to comment.

  • Samer N.

    I think we will make this on Sundays every 2-3 weeks starting in May. If the end project lives at my place, I will waive the consumables cost. However, we will still build a shelf in the 101 class or something similar and I think the 101 class can stay at NL and the rest can be at Samer's Hangar and FlugZeug Werke.

    March 31, 2014

  • Tyler

    Yes, let's build at your place. Not nearly enough room at Nova Labs.

    March 31, 2014

  • Samer N.

    Ok, so I have heard from 6 folks. If you guys are open to the idea of making it a series, and you want to move forward we will skip solid riveting and do it all with blind rivets. However, are you open to the idea of doing this chez moi just because I have all the parts and tools here to cut and slice and dice everything here and I don't have to lug it over?

    March 30, 2014

    • Charles G.

      Interested but not sure I have the time. Where do you live and when were you thinking of doing it?

      March 31, 2014

  • Kyle G.

    it was a really fun and informative.

    March 30, 2014

  • Tyler

    Samer, I'm definitely interested in more classes and building Go Kart, would like to see how these materials and structures hold up in real time!

    March 30, 2014

  • Alex L.

    I really enjoyed this workshop despite that my hands were still throbbing, beet red, and lava hot when I went to bed last night.

    March 30, 2014

  • Samer N.

    I needed to be less ambitious with my tasks

    March 30, 2014

  • Samer N.

    Thanks Jack. If you guys are interested, I am going to send a Chatter message out to see if I can garner interest in a series where we build something. I like vehicles and figure a Go Kart or 'mini-tracked vehicle' that seats one would be interesting.

    March 30, 2014

  • Jack W.

    Really enjoyed the class and appreciate Samer opening up a couple extra slots to accommodate interest. I knew absolutely nothing about metal working before the class but now I can imagine a bunch of projects with just the techniques learned in this intro class. I'd definitely be interested in taking subsequent classes, schedule permitting.

    March 30, 2014

  • Samer N.

    Ok, I can't tell...how do I upload files? The upload button up here appears to be just for a picture...And I can't seem to edit the Wiki....

    March 29, 2014

    • Craig T.

      You need to be logged into nova-labs.org to edit the wiki. Once you've done that you can reply here with the link to the wiki.

      March 30, 2014

  • Samer N.

    It was great to meet and work with everyone. Today I sent Ted a suggestion to do a 101, 102, 103 and 104 class in this as a series, notably to make something as a result of the series. Being a guy who likes machines, I offered that the outcome of the series is a drivable go kart. You guys did the 101 class, but it would be largely building a pop riveted frame for our Kart. The second class (102) would make body panels and 103 class would build the seat and engine mount. 104 would load the engine and add an airfoil at the back and at the end of the class, we take it out to the lot and drive it around. What do you think? You can reach me, BTW, at [masked]. I am going to upload 2 PDFs for your perusal, which should show up here. I will also upload a list of tools and some places where you can get them and the materials. Thanks again for joining me and please feel free to write at any time.

    Samer

    March 29, 2014

  • Samer N.

    Clairut, I suppose I can open this up, but you may be in competition with those waiting. There are 8 of us right now. I will add 2 more spots, but that has to be it because I only have so many rivet guns and drills. So, if you guys are reading this, bring your drills with you. I will bring an extension cord with 3 outlets on it, and pick up another. If there are 10 of us, we will break up into 5 groups of 2, or 3 groups of and I will float. I will schedule a second session in May or June for those who still want to attend. I will also plan on a 102 class where we collectively build a Go Kart from scratch to drive around the parking lot (I have tons of left over parts).

    March 26, 2014

  • Samer N.

    Charles,

    I am not sure, because I was waiting to see how this session went. If folks think it's worth it, then we can do again, probably in May.

    March 7, 2014

  • Charles G.

    Crap, I now have a conflict on this day. If jt fills up and someone needs a spot let me know. Samer, when is the next one planned?

    March 7, 2014

  • Samer N.

    RJ, I don't see why not. You will be learning to use the air hammer in this session anyway.

    Also, BTW, it appears we will be pushing the limits of our time if we worked on the ATV directly, so we will focus our attention on just making the frame(s), one of which I will put on the ATV.

    Samer

    March 6, 2014

  • Tyler

    I haven't done the safety class yet, can I still take this?

    March 6, 2014

  • Samer N.

    If anyone has a specific 'thing' they are working on, let me know about it and I will attempt to tailor some tasks to help you complete it.

    February 9, 2014

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