Toby Bryson
10496670
DTM1104
I intend to build a scarp metal aeroplane suited for a year 9
student. My design will include all the skills I have
developed and learnt throughout the semester.
My plane will be no bigger that 300mm x 500mm x 300mm
and will cost no more than $30. I will make my plane look
aesthetically pleasing and well suited to its functions. I will
incorporate different welding process and different metals
such as cast iron, steel. I want to make my plane sitting on a
stand that is designed form scrap metal. I have to include
minimum one piece of scrap metal, but I intend to use as
much as possible in order to create rustic theme. I also must
include a moving part and a tear drop made from flat bar.
The plane that I want to build is a modern sea plane, I
intend to build the floats of the plane out of the tear drop
element required for this project. The body, wings and
cockpit I want constructed out of scrap metal, in order to
create the rustic theme I intend to design. My plane
shouldn’t exceed the cost of $30 because majority of the
metal that I will used will be scrap metal from home and the
scrap metal bins in the workshop. I will design scrap metal
plate for my plane to sit on. I have collected a Varity of
different types of metals to achieve that side of the design
brief.
 Aesthetically this design is very plain and
simple, hence is a easy construction because it
requires minimal welding and parts.
 The cost of the plane would be very low because
it use very few parts and doesn’t create much
waste.
 This plane design is safe because it doesn’t have
nay sharp edges and wont be heavy so it would
hurt if it fell on someone.
 This plane would suit its functions as a small
desk ornament or a paper weight without
getting in the way ad taking up to much room.
 The measurement of this plane would be no
bigger than 100mm x 100mm x 50mm, I know
this because the body of the plane is a spark
plug and there no bigger than 100mm.
 This plane look aesthetically good, with the large
body and engines in proportion to the rest of the
plane. This would look good in my design
because it allows me to incorporate more scarp
metal for the engines and body.
 This plane would suit the function that I require
for my project, because I require a moving part
and this plane as two for the propellers, which I
could create out of nuts a bolts.
 The cost of this plane design would cost more
than the previous design because it requires
more parts in order to build the propellers.
 The safety of this design would be less because it
has propellers which if not designed well could
be sharp, hence cut someone when there spun.
 The size/measurements of this plane could
depending of the metal and materials available
because it doesn’t, this design is a inspiration and
doesn’t have a set size.
 Aesthetically this plane is very pleasing because
it has a nice recycled/rustic theme and a nice
construct in colours, from using scrap metal.
 This plane would suit its function as desk
ornament or a paper weight well, without taking
up to much room and being to heavy.
 This plane has a positive environmental impact
because it uses scrap metal, which reduces the
amount of meta going to waste.
 This plane wold have a low cost associated with it
because it is made from majority scrap metal,
which doesn’t cost much or is free.
 The safety of this design, is not as good as
previous design because it ahs a lot of little holes
were students fingers could get caught.
 This plane look aesthetically pleasing, because of
the shiny metal finish with a clear coat. Scrap
metal has been used in this design but I don’t
think s well as it could have been, majority of it is
design from rolled plate,.
 The cost of this plate would be small because it
uses scrap metal and some thin sheet metal that
has been rolled, which doesn’t cost much to buy.
 The function of this would be good, as a desk
ornament or display piece, but also it using
bearings as the wheels, which means the plane
should move smoothly.
 The environmental impact of this plane would be
minimal because it uses scrap metal deducing
the amount of waster being produced and metal
not being used.
 The safety of this plane is good, because there
isn't to many spots for fingers to get caught and it
appears that the edges aren’t sharp.
Part
Material
Length
Qty
Total
length
Cost
Total
Body
50mm x 3mm
galvanised pipe
240mm x 50
1
$6.5pm
$1.56
$1.56
Sledges
25mm x 3mm flat
bar
800mm
2
$6.8pm
$8.5
$17
Fin
50mm x 3mm flat
bar
65mm x75mm
1
$7.70pm
$0.5
$0.5
Propeller
25mm x 3mm flat
bar
25mm x30mm
1
$6.8pm
$0.2
Cabin
-
90mm x 40mm
1
$0
Gliders
Roof sheet
120mm x 35mm
1
$0
Wings
Lawn mower blades
330mm x45mm
1
$0
Sledge attaches
Bike chain
50mm x 8mm
4
$0
Propeller
Bearing
50mm 50mm
1
$0
Propeller
Round bar
100mm x 8mm
1
Propeller
Bolt
40mm x 10mm
1
$4.2pm
$0.42
$0.42
$0
$19.48
Week 1, 2nd -8th
Week 2, 9th - 13th
Week 3, 16th – 23th
Week 4 23rd-30th
Designing my plane, with
concept drawings and
research of other planes to
find inspiration, also
planning my design the step
that I take to build my plane
I continued to cut out the
pieces required to continue
building my plane.
Welded the cabin part (cast
iron) to my plane after
practicing and learning the
skill.
I tooked about the chain into
smaller pieces and welded
so they wouldn’t move
Finding and gathering
resources to start to build
my plane
I welded the wings together
and then attached them to
my plane.
I welded the other gliders to
the back of the plane
I attached the guilders to
the body of the plain.
Cutting the flat bar for my
tear drop, then welding and
grinding back the weld
I fushioned weld the sides of
the planes onto the body
I MIG welded the glider at
the back of the plane to the
body.
Removed splatter from the
plane and added a clear
coat.
 First I cut out the flat bar needed to
create my to tear drops, I did this
using the cold saw. I used 25mm x
3mm flat bar in order to create my
tear drops, which were used as my
sledges for my plane. I also cut out
the flat bar that I needed for other
stages of my build.
 I then welded together my tear drops
using the MIG welder and once that
was done I then, cleaned up the
welder with a grinder to smoothen
them
 I then cut out the galvanised pipe
needed for the body of my plane,
using the cold saw. After I cut out the
pipe I the cut and angle along the
side so I could squash the then end
and create a point for the end of my
plane.
 I then cut out used some the flat bar
that I cut out earlier for the sides of
the body on the plane. I cut these to
shape using the cutting disc on the
grind and then used the final shaping
to the grinding stone. I then fusioned
welded this to the pipe
 Next I got my lawn mower blades and
removed any sharp edges from when
the were used, I the over lapped
these and welded them to each other.
I attached the wings to the plane
using a MIG welder as well.
 The next step was one of the most difficult
problems I faced in the construction of my
plane, I had a scrap piece of cast iron which I
wonted to weld to my plane as the cabin, the
difficulty with this I I couldn’t weld it with the
MIG and after talking to my a couple lectures
and researching the only way I could weld this
was to braze weld it, but what I was told my the
lectures is it’s difficult because it often cracks
because of it crystalline structure, I in order to
ovoid it from cracking I had to evenly heat up
the piece of cast iron and then once welded it I
had to let it cool down slowly (without water).
Before I welded my final piece I practice with a
other scrap piece, this first result was
successful and helped me learn the skills
required. I then welded my final piece, which I
had issues heating up evenly because of the
different thicknesses, but evenly I was able to
successfully weld it without it cracking.
 I then started to create the
gliders/wings at the back of the
plane. I first cut some 50mm x 3mm to
create the gliders, I then cut of the
corner and attach it to the bottom the
create the intented shape, once I had
mig welded it I ground down the
weld to create a smoother finish.
Once I finished the glider I the cut a
section of the scrap roofing sheet,
using a cutting disc, which I used to
create the second wings.
 I then took about the chain, until I had
four piece of four links. I did this
through using a centre punch and a
hammer. Once I had collected my
four pieces I welded my chain pieces
so that they couldn’t move, then to my
sledges. The chain pieces are to
attach the sledges to the body of the
plain.
 Then is started to create the parts for
the propeller, first I bent the round
bar into a semicircle to fill the gap
between bearing and the cabin.
Once I had welded the round bar to
the plane I welded the bearing to the
plane as well, but in this process I
seized up my bearing so it would
move, so I had to determine a new
moving part.
 I then created the propeller for my
plane using the grinders. I then
ground down my bolt so the
propeller would spin, because of the
bearing seizing up. I used a washer
to stop the propeller of falling off, I
welded the bolt to the bearing along
with the washer to the bolt, I did all
these with the MIG welder.
 The final step of my plane was
removing any splatter form the
welder as well as an burn
smoke/burn marks for the brazing
and welding processes.
 My final design I built a sea plane, I built most of it out of scrap metal, because my
intended design was to have a scrap metal/recycled theme. I continued this idea,
by not grinding or polishing my plane, but instead I cleared coat it. Overall I think
my plane turned out pretty good, apart from minor issued, which came from trying
to join/balance different scrap metal objects, create cause them to be slightly
uneven. The biggest problem I had was trying to weld the cast iron to by plane, in
order to achieved this I had to do research and talk to my lectures in order to learn
how to do it. I think my project would be good for student, because it removes and
creates a purpose for scrap metal which it good for the environment.