PLAN
#
Part
Process
Tools and equipment
Quality control
Safety *Aprons must be worn is
ALL stages of manufacture
1
Mark out on MDF piece
Pencil, try square, and
ruler
Measure out right angles with try square to ensure
accuracy and use rule to check all measurements
Basic safety procedures
2
Cut out base+ sides using a tenon saw.
Tenon saw
Make sure you do not go over the markings, cut a few mm
away from marking lines
Basic safety procedures
Briefly sand edges to size
Belt Sander
Use belt protractor while using belt sander to ensure
straight lines.
Eye goggles
4
Mark out base into thirds
Pencil, steel rule, try
square
Use try square to check all right angles and recheck all
measurements
Basic safety procedures
5
Use router where markings were made
Router, G- clamp,
Speed clamp
Eye goggles + mouth mask
6
Briefly file edges made by router
Files
Basic safety procedures
7
measure and mark finger joints to
size(on both edges of each piece)
Pencil, try square, and
rule
Measure out right angles with try square to ensure
accuracy and use rule to check all measurements
Basic safety procedures
Cut out finger joints using coping and
tenon saw
Coping saw, tenon saw
Make sure you do not go over the markings, cut a few mm
away from marking lines
Basic safety procedures
9
Sand out rough edges (using files, after
cutting out joint)
Files and belt sander
Use belt protractor while using belt sander to ensure
straight lines.
Eye goggles
10
Drill holes on each side 30mm from
bottom horizontally
Hand drill
Find exact center where hole is to be drilled and mark
horizontal lines across to find exact center.
Repeat steps [7 – 9] for box front and
back pieces.
-
Repeat quality standards as stated above.
Drill 2 holes in center of box front and fit
handle
Pillar drill, screws
Mark out where holes are to be drilled.
Fit & fix the four sides together
-
Use belt sander to level the joint (to not
have one piece bigger than the other
etc.)
Belt sander
Use try square and steel rule to ensure all cuttings have
been made accurately and all edges are at 90o angles. Use
belt protractor while sanding to ensure all right angled
faces.
14
Mark out both pieces on acrylic piece.
Pencil, rule, try square
Recheck measurements using rule and try square
-
15
Cut out using coping saw. After cutting to
size…
- Cut 1 piece 50mm from the edge
[horizontally] and 30mm downwards
from the top.
Coping saw, rule,
pencil & try square
Leave out a 2-3mm gap away from marking lines while
cutting so that it can be sanded to size later. Check right
angles at various intervals to ensure correct length and
width.
Basic safety (hair tied
back, sleeves up etc.)
Use cross filing and through filing
techniques to smooth edges, wet and
dry paper and buffer.
Files, wet and dry
paper and buffer.
Use a file to wrap wet and dry paper around to level
surface while filing.
Basic safety procedures
3
MDF base
8
Box sides
( x
2 )
11
Box front
and back.
Eye goggles and basic
safety procedures.
12
13
16
Eye goggles
Sides and
frond +
b a c k
Acrylic
pieces
( x 2 )
Eye goggles
Tim
e
Safety *Aprons must
#
Part
Process
Tools and equipment
Quality control
be worn is ALL stages
of manufacture
21
Fix pieces together
PVA glue
-
Briefly sand edges
Files
Use appropriate files in comparison to area and
length
-
23
Smooth surfaces
Glass paper
Use a cork block to keep surface leveled
-
24
Mark and draw to correct sizes on CorelDraw
Computer – CorelDraw
software
Recheck all measurements before cutting out. Briefly
file edges to level
-
Use CNC Laser Cutter to cut out shape
CNC laser cutter
Recheck all measurements before cutting out
-
Measure 30mm from the bottom & make a
horizontal line
Rule, try square & pen
Take acrylic protective sheet off before marking to
insure accurate bending
Eye goggles face
mask
27
Bend 45o
Strip heater
Place wooden scrap blocks (away from heat line) to
keep acrylic in place
Gloves (when
lifting)
28
Drill 2 holes on each side of ‘Box front’ for
locks
Hand drill, screws
Mark out where hole is to be drilled. Use hand vice
while drilling holes
Eye goggles
29
Use Cold chisel to cut off 2 mm to place
hinges on top side of box back.
Chisel , mallet
Cut on waste side so that the cut is not gone in too far
-
30
Drill 3 holes for hinges on the top side of box
back
Hand drill
Make indent where holes are to be drilled
Eye goggles
31
Join box lid to box using hinges
Screw driver, screws
Don’t tighten too much with screw driver so that the
holes don’t get loosened.
-
32
Assemble all sides and base (not lid or
acrylic bits)
PVA glue
Tighten a lot so that it is fixed securely
-
33
Clamp assembled piece together – allow to
dry and fix
Clamps
-
-
34
Use filler to fill any gaps after fixing
Filler
Don’t use too much so that it doesn't’ come off when
sanded
35
Sand surfaces after filler dries
Belt sander
Go near mark lines however not over them so that too
much isn't sanded off
Eye goggles
36
Seal all wood pieces –all dimensions
PVA glue mixed with water
Check at right angles to ensure accurate assembly.
-
37
Apply first coat of primer on wood pieces.
Primer
Use thin coats so that paint spots aren't too heavy in
places - evenly spray layers
Face mask, eye
goggles
38
Smooth surface
Glass paper
Use cork block to sand evenly so that the surface is
leveled
-
Repeat the previous two steps to give 3/4
layers of primer
-
-
-
Smooth surface again before applying paint
Glass paper, cork block
22
Balsa Lid
25
26
Acrylic
canvas
Joining
39
40
Wood
Finishing
Use cork block to keep surface leveled
Time