How I Reinforced a Weak Frame (Part 1 of 2)


     The picture above is a list of possible projects that can be made in the workshop during the year. We have just split off into individual projects based on the jobs we are aiming for during adulthood. Mr. Grosinger will choose our projects based on his experience on projects.


     This picture displays an excel sheet from my Green Technology class and the assignments that he had assigned for the class that he think will be of great assistance in our future. His choices will be based on our long term goals, which in my case was a mechanical engineer or an architect.


     This picture contains what is called metal shears which is used to cut a small amount of metal into desired pieces or to make sharp corners into radius corners for safety reasons. I also used a tri-square which is is used as a ruler and contains a perfect 90 degree angle for a straight line.


     This picture is when my project really starts when I am assigned to help reinforce a metal shelf that needs to hold around 400 lbs for a science project. The technique we decided to use was the addition of gussets which hold a 90 degree angle that can be added to corners to support the shelf from swaying.


     The picture above displays a very important diagram which describes tolerance and shows our tolerance for each hole in the gusset. Since the frame is hollow we have a specific tolerance that we have to be inside in order for our gussets to work and successfully support the frame.


     The picture above shows me using a tri-square with a marked measurement that will show me if the holes are within the tolerance which will tell me if the gussets can be used now or if they need to adjusted to fit the right requirements. 

    
      In the previous description I stated that some gussets will need to be adjusted and the way I would adjust them is by cutting the excess metal that puts the holes out of the tolerance. I could use the metal shears displayed earlier in the blog however I used a bigger version that can cut metal on a bigger scale.


     This picture is an important one as it displays a technique that will make checking each gusset significantly easier. I first used sharpie to color in a section above the hole then I used a caliper and measured the tolerance and scratched the metal over the sharpie in order to get a fine measurement of the tolerance.


     This picture just displays the new technique on the diagram used earlier in this blog and used to determine a hole that was too close to call using basic judgement.


     The picture above shows a piece of metal that was rolled using a bead roller to not only add design but also strength to the gusset. However the bead roller would cause problems to the gusset such as an excess of metal in a few sections so for that we would use a "shrinker" to even out that excess count of metal.


     This picture contains a sheet of metal connected to a steel rod using a rivet. The hole on the rod was made using a drill press and the hole in the aluminum sheet was made using a metal hole puncher. This was going to be the technique used to attach the rivet to the frame, first drilling holes into the frame and using rivets to attach them both together.


     This picture shows a finished gusset with a design using the bead roller, "shrinked", and cleaned with sandpaper to make the gusset shine to attract almost anyone.


     This picture shows a gusset clamped to the frame so I can drill the holes into the frame in order for me to use the rivets. Once there were 6 rivets on the gusset I would remove the clamps to finish drilling all the holes and using rivets on all the holes.


     This picture shows a different gusset with my partner's and my name stamped into the gusset to personalize the gusset and so that we have proof of us working on this frame. This also displays what a finished gusset looks like.


     This picture shows a classmates gusset being added on as well after I showed them how to attach the clamps onto the gussets, drilling the holes into the frame, and correctly using rivets to secure the gusset on.




















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