HEAVY FILING
If there are any low spots the light will show through so that I can file the high spots. When the edge is straight no light shows through.
SAFETY A FILE MUST NEVER BE USED WITHOUT A HANDLE.
The end of the file that fits into the handle is called the TANG. If the file is used without the handle the tang can and will quite easily injure the wrist. As the handles are not very secure, perhaps an improvement would be to glue them in place.
METHOD OF FILING TO GET A FLAT EDGE
ARROWS SHOW DIRECTION OF CUT.
MAKING ONE END SQUARE TO THE STRAIGHT EDGE
METHOD
Using an ENGINEERS SQUARE and a FILE I used a similar method to the straight edge except that instead of the ruler I placed the engineers square against the straight edge. The blade was used to look for the high and low points on the end.
LIGHT SHOWS UP LOW SPOTS,
WHEN AT 90 DEGREES AND FLAT,
NO LIGHT SHOWS THROUGH
ENGINEERS SQUARE
WORKPIECE
SAFETY
Filing causes sharp edges which can cut hands. I used the file to make these edges safe.
MARKING OUT THE HOOK.
Once I had one end square to one edge I could mark out the bending lines and the position of the two holes for the rivets. First of all I painted the surfaces of the hook with engineers blue, making sure none of it got in my eyes. Using the surface plate and a scribing block I found the centre line along the hook section. I then used an engineers square to mark off the lines. All of the lines were marked from the square end to reduce the risk of accumulative error. The diagram below shows all of the marking out for drilling and bending. After drilling the two 3.2mm holes I marked the end radius for filing using spring dividers as shown.
FILING ENDS
I filed the end radius by filing up to the marked lines. The radius was 11mm or half the width of the hook. I followed the safety procedures for filing.
BENDING
Using a 45degree and a 60degree template and the FOLDER I bent the hook to the shape shown on the drawing.
It is easy to trap fingers in the folder so I kept my hands clear during this operation.
FINISHING
Once all operations on the hook were complete I cleaned off all of the marking blue and made sure all edges were smooth and presentable. I used emery cloth and wet or dry paper to achieve a surface good enough to spray with paint.
I put the hook to one side and started the BACK PLATE.
TO DO
Back Plate
Marking out
Filing 4 corners
Drill and c\sink
Rivet
Clean up and paint