Shop Problems in Sheet Metal

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SHOP PROBLEMS
IN SHEET METAL
FOR SECONDARY SCHOOLS
WITH NOTES ON EQUIPMENT, MATERIALS

AND SHOP METHODS
By
EUGENE' C. GRAHAM
Director Vocational Education

Evansville; Indiana
PRINTED ON THE HIGH SCHOOL PRESS

EVANSVILLE. INDIANA
1918
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COPYRIGHT, 1918,
EUGENE C. GRAHAM
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Shop Problems in Sheet Metal
THE TRADE OF THE SHEET METAL WORKER.

As an i n troduction t o this l i ttle coll ection of n otes and drawings the author
wishes to call the atten tion of H igh School boys especiall y to the f act that this
trade h as not receiv e d the attenti on it deserves f rom the school s. In recent years
several v ocations such as pri n ting , concrete constructio n , automobile repair a n d
el ectrical w o r k h av e f o u n d a place i n the schools while others seem to b e l osing
ground. I t seems to be true that trades such as bl acksm ithing a n d m ol di ng
wh ich h av e been i n fl uenced by the i ntroduction of n ew m achi nery which i s m ore
or l ess aut'lm atic, h av e become l ess attractive to boys.
Sheet m etal work as a v ocation h as m an y attractiv e f eatures. I t i s a l arg e
an d g rowing in dustry represented b oth i n the buil di ng trades and i n m o dern
autom ob il e constructio n , f urniture and b oat buil ding and in the constructi o n
of m an uf actured articles. The i n troducti on of autogenous wel d i ng an d el ctric
wel ding has done m uch to make p ossible the use of sheet m etal i n new f orm s .
All well trained sheet m etal workers can draft t\J e i r o w n patterns. B oys
who h av e been un able to see any use f or i ntersections and devel opm ents i n
m ch a n ical drawing can q uickl y see the relation between this b ranch of drawing
an d the draf ting of patterns.
The working of m etal in sheet f o rm is l ight, in teresting and i nstructive. The
m a king of ki tchen utensils, such as pans, sug a r scoops, fun nel s , d ust pans, can
teens, b read boxes and other articl es is attractive to m ost boys. A l arg e n um
ber of h a n d operated m ach ines are used and the t raining aff orded by these m a
ch i n es is v al uable. B oys l i ke wood turning because they can run the m achi nes
f o r themselv es. I n the sam e way they become in terested in the m achi nes used
to bend an d shape sheet met al and can m a ke a l arger v ariety of usef ul p roducts
than in nearl y any other sch ool sho p .
B oys w h o are in terested in the trade wil\ fi n d that the wag es p a i d are better
than in some other related trades and that there is al ways a dem an d f or com
p e tent m e n .
T h e author hopes to add to th is collection of drawings from time to time
a n d will welcome sugg estions a n d criticisms. The n o tes are m erel y a ba re out
l i n e of rel at ed f acts a n d sh o ul d be supplemented by outsi de readi ng and v isits
to shops where sheet m etal is used.
Credit is due the P eck, Stow and Wilcox Co., of South ing t o n , Conn., f o r
t h e el ectrot ypes used. The list of eq uipm e n t is from their " P ex to" l ine, which
h as been used with satisf action by m any schools.
Page One
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MATERIALS USED BY THE SHEET METAL WORKER.
Articl es m a d e of sheet m etal arc comm onl y made either of tin plate, sheet
iron o r g alv anized iron. O ther kinds of sheet m etal sometimes used. are sheet
c o pp er, sheet alum i n um, sheet z i n c or sheet b rass. E ach of these m aterial s has
som e special advantages but it m ay be said that if we coul d neglect the i tem of
first .cost either sheet copper or sheet al um inum woul d take the place of m ost of
the other m aterial s. A short parag rap h o n the qual ities of each of the abov e m a
terial s i s given b el ow.
Tin Plate.
I t is often a surprise to a pupil to fi n d that ev en g o o d tin pl ate is n o t m ade

of pure tin. Since i t is cov ered with a metal so different f rom iron in appear
a nce i t i s n o t easily discov ered that it is m ade of sheets of i ro n cov ered o n both
sides w i th a coating of t i n . T h e thickness of this coating v aries som ewhat with
t h e q ual ity b u t it i s nev er v ery thick. I t is put o n by dipping pl ates of iron
which have been caref ull y cleaned in aci d and scrubbed with sand and water,
i nt o tanks of m el ted tin. T h e tin forms a k i n d of an all o y with the iron i n the
plate and af ter p assing through the b ath of tin one or m ore times and being
carefull y cleaned and inspected it becomes a sheet of tin pl ate. Sometimes lead
is m i xe d with the tin an( with this c hange " terne" pl ates are m ade f o r roofing
bU il dings.
T i n plate is easily worked, is not easily aff ected by air or water, takes sol
der well and can be kept b rig h t an d cl ean without m uch troubl e. I t i s the cheap
est m aterial used f o r kitchen ware.
Sheets of tin are usuall y 20 x28 i n ches in size, but they may be had h alf that
siz e o r 14x20 i nches a n d sev eral other sizes are m ade. In thickness they run
f rom 20 wire g auge to 30 and they m ay h av e f rom one to three coats of t i n .
Articl es m a d e of t i n plate a r e of ten retinned af ter m a n uf acture. T hi s can n o t b e
d one wi th sol dered work. Why?
Sheet Iron.
Plates of soft sheet i ron are used for roasting pans, stove p i pe and as a l i n
ing f o r ovens. When of nearl y pure iron and treated with a process to p rev e n t
rust i t becomes a g ood m aterial f o r l imited uses. I t cannot be s ol dered a n d i s
easily affected by water and acids.
Galvanized Iron.
G alv anized i ro n i s sheet iron 01' steel coated with z i nc, som ewhat as tin
pl ate i s coated with tin. The zinc coating m a kes i t rust proof f o r a l o ng time
and g iv e s i t a pl easi ng appearance. H owever the z inc will not stand acids and
i s l i kel y t o p eel off i n fl akes if the m etal is hamm ered or bent. I t does n o t polish
well b u t can be kept cl ean by wash ing . I t is not used in m aking kitchen ware
but f o r d ry m easures, roofing, etc i t i in comm on us e.
G alv anized sh eets are usually 30 i n ches wide and 96 in ches l ong. Wi der and
l ong er sheets m ay be bought. T h e thickness runs f rom 16 wire g auge or thicker

d own t o 30 w i re g auge. G alv anized sheets f r om 24 to 30 g aug e are m ost com
m only used i n schools.
Page Two
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Sheet Copper.
This metal c om es i n sheets nearl y p ure and c a n b e had i n m an y thick nesses
and sizes. When used b y the sheet m etal worker i t has m a n y fi n e qual i ties and
c a n b e drawn, h amm ered, sol dered, a n d pressed i n to m a n y shapes. I t i s tough
an d stands working b etter than m ost metal s. I t c a n be anneal e d o r m ad e soft
b y heating a n d q uenc hing in water. When m ade i n t o utensils it is usuall y tinned
and of ten n i ck el plated o n the o utside of the vessel. P u re c opper i s som ewhat
a c te d on by the air a n d b y water and m ore b y aci ds, so that t i n n i ng i s nec es
sary f o r some p u rposes. O n ac c ou n t of the c o s t i t is n o t m u c h used, b u t i s a
very durabl e roofing m aterial. Copper is used f o r m an y articles which are beat
e n i n t o shape b y hammering.
Sheet Zinc.
This m etal has m a n y v al uabl e qual ities a n d i s used f o r roofing, t o ps f o r
k i tc h e n c ab i nets, ornam e n tal v ases, etc. I t i s v ery l i ttle acted o n b y the a i r af ter
the first film of o x i d e f o rm s on the surf ac e. I t may be sol dered if c are is tak en
to av o i d burning throug h the m etal with a c opper which is too h o t. D il ute m u
riatic a c i d i s used as a fl u x i n sol dering z i n c.
Sheet Brass.
Sheet b rass has m a n y of the qual i ties of c o p pe r. I t is somewhat harder and
req u i res m ore c are in b e nding. B y anneal ing i t c a refully it m a y b e worked i n t o
m a n y shapes. B orax m a y b e used a s a fl u x i n sol dering b rass. B ec ause of the
inc reased c o s t i t is n o t m u c h used except i n some m a n uf a c t u red articles such as
automobile l am ps.
Sheet Aluminum.
This m etal is c om i ng i n to v e ry g eneral use f o r k i tc he n utensils. I t i s v ery
durable a n d easily kept clean. It is not much ac ted o n by the air or by water
a n d a c i ds, b u t al kal ies have some aff e c t o n it. Since i ts m elting point i s m uc h
l ower than that of c opper an d iron i t m a y b e m el te d through o n a hot range if
the v essel b oils d ry. I t is v ery easily worked a n d m a y b e pressed and drawn
i n t o v arious shapes. S i n c e i t c an n o t be sol d ered with m uc h succ ess it m ust
either be welded or riveted. Many a rticles are c ast i n t o shape. Al um i n um rivets
shoul d b e used f o r f asten ing handl es and other attached p arts.
Pane Three
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The Folding Machine.
I n o rder to turn a hem or lock o n the edge of a pi ece of sheet m e t al some
means m ust be f oun d of h ol di n g the m etal fi rml y whi l e the edge is b ei n g turned.
O r we m ay gri p the edge and turn the f ol d by m ovi n g tbe pi ece i tself . The or
di nary f ol de r does the l atter. Other m achi nes are used c all ed open throat f ol d
ers which use the f o rm e r m ethod.
These m achi nes will al so prepar e the edge of sheet m etal t o receiv e a wi re
All f ol ders h av e adjustm ents to re gul ate the wi dth of the f ol d a n d al so the
s h ar p n ess of be n d, so that they m ay slso be used to prepare the edge of sheets to
re ceive a wi re. I t is al ways necessary to know j ust how the m achi ne is adj usted
bef ore attempti n g to m'l ke a f o l d or to wi re an edge.
The Grooving Machine.

Af ter a l o c k seam has been f ol de d o n the f ol der i t shoul d be cl osed down
wi th a groov e d wheel o n the groovi n g m achine. H a n d tools are al so used f o r
thi s b u t i n all cases where i t i s possible t o use the machi n e i t i s better t o do so.
The groovi n g rolls are made to fi t several wi dths of seam and the proper r oll
shoul d be used.
The Brake.
This m achi ne, comm o n l y cal led t h e cornice bra ke, has a wi der range of use
f ul ness than the fol der. I t m ay b e u sed t o turn hems o r f ol ds and also to m ake
bends a t all angl es u p t o nearl y 180 degrees, and a t any di stance f rom the edge.
The brake al so has attachm ents for f o rmi n g m ol de d shapes to alm ost any pat
tern. Lengths up t o ei ght f eet are i n comm o n use.
I n usi n g this m achi n e i t is necessary to plan the bends to be m ade if sev
eral are to b e turned' i n the same piece. Otherwise the pupil will fi n d i t hard to
deci de what the order of operati ons shoul d be.
I t i s advi sable to m ark the l ocati o n of li nes and bends with punch m arks.
li n e m ay t h us be transf erred to th e ot her si de of the sheet accuratel y .
F o o t levers are provided t o hol d the w o r k tem poraril y, b u t i t i s q ui te im p o r

tant that the cam levers shoul d be used to cl am p the work i n pl ace. P u pils
shoul d nev e r attem p t to ben d heavy m etal or wire in this m achi n e.
The Wiring Machine.

After the use of the turni n g m achi ne the wi re i s fi tted to i t s pl ace and part
l y cl os e d i n wi th a m all et. Then the wiri n g m achi n e i s used to tuck i n the e dge
of the me tal neatly around the wi re. Some j udgm e n t is needed to set the m a
chi ne f or diff erent sizes of wi re.
This m achi ne m a y al so be used to wi re the edges of fl a t work. P ai n s shoul d
be taken t o keep the surface of the flat w o r k horizontal o r to rai se the
outer e dge a little i n order t o p rev ent a ri dge bei n g form ed on the l ower si de
of the work.
Page Five
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The Turning Machine.
T urning m achines are used to pre pare t he e dge of a c an bo dX or other simi
l ar work such as t he e dge of a f unnel to receive a wire . When such '"York i s
re a dy i t i s pl ace d o n t he lo wer groove d roll an d again st the g u age. T he scre w
i s t urne d until t he upper roll forms l! slight groove in t he work. After one revo
l ution t he work i s tilte d upwar d a little an d t he scre w tightene d un til a deeper
groove i s forme d . By repeating t hi s operation an d m aking sever al revolutions
of t he work the e dge i s pre pare d to receive the wire. To avoid some of the mo st
common f ault s of beginner s, try to t urn slo wly at first an d to pre ss t he 'i'/ork
firmly again st t he g u age . After tilting the work upwar d do not allo w it to'drop
back again. Do not force t he roll s ag ain st t he met al.
Pr actice on some c an
bodies which h ave been c ut down from disc ar de d tom ato c an s to a height of
abo ut t hree inche s . Serviceable tin cups may be m ade of t he se by wiring t he
to p e dge an d sol dering on a ne at h an dle . Skill will come wit h practice.
The Burring Machine.

T hi s m ac hine is use d for t urning an e dge on cylin der s of metal or on di scf>
such as c an bottoms. In pre paring vessel s for do uble se aming a b urr i s first
t urne d at a right angle on t he bo dy nn d t hen one of the same wi dth on t he e dge
of t he bottom . T hi s l ast o per ation i s q uite dif fic ult an d takes con si der able
practice. Bottoms c an be m ade m uc h better on a circ ul ar she ar with a fl anging
att ac hment.
In using the burring m ac hine remember t h at only a n arrow burr about one
eighth of an inch wi de c an be t urned. T he b urring m ac hine i s the hardest m a
c hine for beginners to u se. T he pupil sho ul d avoi d spoiling goo d m ateri al un
til he has h a d c areful in str uction.
The Setting Down Machine.

T hi s i s u se d to close the se ams left by t he b urring m ac hine. It i s very sim
ple an d m ay be t urne d in either direction. It has no adjustment s e xce pt for
t hickness of m ateri al .
Page Six
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NOTES ON SOME OF THE MORE COMMON METALS AND ALLOYS
I ro n is a very c omm on m etal. I t i s found i n m a n y c o untries an d especi ally
in the U ni ted S tates. The m ines near lake S uperior on what is c alled the I ron
R ange, and other m ines near B i rm i ng h am , Alab am a , p ro duce g reat q uanti ties
o f iron o re . These o res are m elted with lime stone, c oal and c oke in b last fur
n ac es which are ab o u t e ighty feet high a n d twenty feet i n diam eter i nside. These
furnaces m ust be kept g o i ng n ig h t and day. The m elted i ron i s c as t i n t o i ng ots
"
c alled p ig s" , or it m a y be m ade i n t o steel in a B essem e r c onverter. Wrought
i ro n is m ade from c ast iron b y rem ov ing im puri ties. Cast i ron c on tains c arb on ,
sulphur, silic o n , phosphorus and other elem en ts i n v arying proportions. These
im purities m ake the c ast iron b ri ttle and weak as c om p ared with steel and
wroug h t iron.
.
S teel c on tains elem e n ts like c arb ofi , m anganese, n ic kel, etc ., in q uite definite
proportion s a n d b y v arying these p roportions the m anufac turer c an produc e
steel fi t for steel b eam s, raz o r b lades o r watc h springs a n d a h un dred other
pro duc ts, as he chooses.
Iron
I ro n i s a silv ery m etal with a density o f 7 .86, a melting p o i n t o f 2754 deg rees
an d a weig h t per c ub ic foot o f 480 Ib s.
I t is duc tile and m alleable and alm ost as soft as alum i num . In the in dustries
pure iron is seldom used. What is c alled m ild steel is c omm only used in i t s
place.
Copper
Metallic copper has b een kn own from the earliest times a n d was p rob ab ly
one of the fi rst m etals in use. It i s a h eav y m etal of a reddish c olor with a
density o f ab out 8.9 3 . I t m elts a t 1 948 deg rees and weighs 552 Ibs. per c ub ic
foo t. I t i s rather soft and is very duc tile, m alleable and flexib le, yet tough and
fairly strong . It is a v ery g oo d c on ductor o f heat and elec t ric i ty. Copper is used
for m aking alloys, for roofing , for elect rical c o n duc tors and m an y othe r p u r
poses. I t c an b e rolled into sheets, hRlllm ered i n t o shapes or drawn i n t o wire.
Lead
Lead has b een k n own from v ery t arly tim es. The R om ans used i t for water
p ipes, as we do n o w. It is a silvery m etal o f density 1 1 .37 , which melts at 588.6
deg rees. O ne c ub ic foot o f lead weighs 7 10 lbs. While i t is heav i e r than most
m e tals there are som e, such as g old and plati n um , which a re m uc h heav ier. I t
i s v ery l i ttle affec ted b y air or h ard water and is used for pipes , for alloys a n d
i n m an y k i n ds o f paint. Sheet lead is often used f o r lin ing tanks a n d lead plates
are us e d in storag e batteries.
Tin
T i n is a silver white m etal harder than lead and q uite m alleable. I t has a
densi ty ab o u t 7 :29 and a m elting p o i n t o f 4 18.5 deg rees. I t weighs 458 p o u n ds
p e r c ub ic foot. Tin is used in the m anu fac ture of alloys and as a c oating for
sheet steel to m ake tin plate. P ure tin is used as t i n foil, but c om p ared with
o ther m etals i t is n o t o ften used in this form .
Page Seven
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Zinc
Z i n c is a blu ish white m etal . I t h as a density of 7 . 10 a n d a m el ting po i n t of

754.9 degrees. I t weighs about 436 pou n ds per cu bic foo t. A t som e tem pera
tu res i t is b rittle bu t between 250 an d 300 deg rees i t m a y be roll e d i n to sheets
a n d is then of g reat u se as a sheet m etal . Since i t i s cheaper than co pper an d
l ig hter than l ead i t i s u sed fo r roofs, gutters and architectu ral o rn am e n ts. I ts
chief u ses are i n the m anufacture of alloys and i n the co ating of steel p ipes and
plates. T h i s p rocess i s call e d g alvan iz ing . T h e o x i de of z i n c is used i n m a k i ng
pai nts, a n d z i nc ro ds and bars are u sed in batteries.
Aluminum
Alum i num resem bl es tin i n appearance. I t h as a density of o nl y 2.65 a n d is
therefo r e o nl y abou t o ne- third as heavy as i ro n . O n e cu bic foo t weig h s 166.5
pou n ds . I t m el ts at 1 185 .3 degrees. I t is du ctile and m alleable except at low and
high tem p e ratu res. I t is f ai rl y h ard and stro ng . Sheet an d cast alum i num are
u se d fo r coo king u tensil s. Alum inum wire is u sed fo r co n ductors. Aluminum
z i n c alloys are u sed in castings fo r au tomo bil e p arts.
Alloys
An allo y is a m i x tu re o r com b i nation of two o r mo re m etal s to o btain cer
tain desirable p ro perties. T h ese m etal s will i n m a n y cases u ni te i n a g reat m any
differen t p ro po rtions, but to secu re the de sired p ro perties o nl y certain d e fi ni te
m i x tu res are commonly u sed. The adv an tag es ob tained are i ncreases i n streng th,
h ar dness, tough n ess o r el asticity, a lower m el ti ng poi n t o r to f acil i tate the p ro
du ction of sou n d castings.
Som e of the mo re im po rtant allo ys are as follows:
B r ass
Aluminum bro nz e
Germ an Silver
Mang a n ese bronze
B ro nz e
B ell m etal
P ho spho r b ro nz e
Sol der
P ewter
Made
"
"
"
"
"
"
"
"
of
"
"
"
"
"
"
"
"
Co pper and z inc

Co pper a n d alum inum
Co pper, z i n c and nickel
Co pper, z i nc, iron and m a ng anese
Co pper and tin
Co pper and tin
Co p per, tin an d phosphorus
T i n and l ead
T i n , antimo n y , co pper and bismu th
O nl y a f ew of these allo ys are used by the sheet m etal wo rker. Sheet b rass
m a y take the place of cheaper m aterials fo r som e wo rk. Sof t sol der, m a d e of
t i n a n d lead, o r hard sol ders made of co p per and z i nc, are of g reat impo rtance.
Palle Eight
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SOLDERING FLUXES.
A fl u x i s a m a terial in any f orm , powder, paste o r l iq ui d , which h el p s to
make the solder unite m ore easily with the m etal. Most of these fluxes h av e
some chem ical acti o n o n the m etals b u t some appear t o d o l ittl e b u t keep the
sol der fl o wing easily.
A g ood fl u x f o r o n e k i n d of m etal m ay flO t work well o n others.
sta n ce rosi n will n o t work well o n anyth i ng b u t brigh t t i n .
For i n
A l ist of t h e m ore comm onl y used fl uxes f oll ows :

R osin- ei ther p owdered o r dissolv ed in g asol i n e o r turpen tine.
new work o n tin pl ate.
U sed f o r
Z in c Chl ori de-made by cutting z i n c with m uriatic acid or by m ixing the com
m ercial z in c chl ori de with water. U sed g en erall y f o r all work.
R a w M uriatic Aci d- also calle d hydrochl oric aci d , generally dil uted w i th
water, som etim es m ixed with the zi nc chl oride flux. U sed f o r z i nc, also f or
g alv aniz e d i ro n .
Comm ercial sol dering paste- co n taining v arious m i x tures.
trical work.
U se d f o r elec
B orax- i n p o w dered or dissolv e d f o rm , used for brass .
RIVETING
Sheet m etal m ay be f astened together fi rmly by riveting and m any times
where strength is necessary both rivets an d solder are used. The size of the
rivets used depends b o th o n the thickness of the metal and o n the strength r e
q ui re d i n the j oi n t.
"
The tin ner usually sets his rivets by what is call e d bl i n d riv eting." H e
pl aces the rivet un der the sheets of m etal a n d draws i t throug h by driv i ng a
riv e t " set" over i t with a h amm er. This p rocess req uires som e p ractice b u t
m a kes a v ery firm j o i n t because t h e rivet always fits t h e h ol e and m ay be drawn
up v ery tightly. O n some l ight work the rivet som etimes spreads out and
stretches the m etal aroun d it. For this reason a n d because i t is easier to place
them accuratel y , rivets m ay be set in h oles al ready punched i n the sheets of
m etal . This is al ways done i n heavy work. This process is recomm ended f o r b e
g i n ners and the holes sho ul d be caref ully l o cated an d p unched with a sol i d punch
over a bl ock of w o o d on end g rain.
In heading a rivet a lig h t h amm er is us ed an d l ig h t bl ows which f o rm a head
on the rivet sl owl y are necessary f o r g o o d work. Use the rivet set to f orm a
sm o o th head o n the rivet.
T i n ners' rivets, which are usually coated wi th tin are sol d by the b o x and
a':"e n um bered 8 oz . o r 10 or 12 o r 14 oz ., which m eans that 1 ,000 rivets of o n e
sIz e weigh a certain n um ber of o unces. Larg e r rivets f rom 1 l b . up to 1 6 I b s .
a r e sol d , which a r e rated i n p ounds o r p e r thousan d.
Page Nine
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HOW TO SOLDER.
.
T here are n o secrets about the use of sol der which m a y n o t be learn e d b y
t h e b eg inn er, b u t the skill of the g o o d m echanic does n o t come without m an y
h o urs of p ractice. T h in king whil e you a r e working will shorten t h e l earning
of the p rocess m ore than an ything else you can do.
O rdinary soft sol der i s an all oy of tin an d lead, usually about h alf an d h alf .
I t m el ts at about 350 deg rees an d un i tes easily with tin , l ead, z inc, copper an d
brass, b u t n o t easily w i th iron or steel.
There are f o ur im portan t p rinciples to be rem em b ered by an y on e who at
tem p ts t o sol der :1.
T h e sol dering copper m ust be kept clean an d well tinn ed.
2.
A g oo d soldering fl ux m ust be used, an d one which is suited to the m etal .
3.
T h e m etal s t o b e sol dered m ust b e cl ean .
4.
T h e j o in t m ust be heate d above the m el ting p oin t of the sol der.
Sol dering req u i res heat. Y o u may use g as, coal o r charcoal o r a g asoline
torch to heat the coppers. If you use g as take care n o t to l e t the copper get
sm oked up in the yell ow p art of the fl ame. The bl ue flame is h otter,
T o try if the copper is h o t en ough you m ay touch i t to a l um p of sol der,
h ol d i t n ear your f ace to test the h eat. Do not overheat the copper or the
tin will be burn e d off .
01
When you are ready to solder a j oin t, see that the surf aces fi t well an d are
cl ean . Appl y the sol dering fl ux to the j oin t with a sm all brush. D o n o t spread
the fl ux over a w i d e surface. T o uch the hot copper to the en d of a bar of sol der
an d then to the joint. See that onl y a n arrow edge of the copper touches the
j oin t. T ry to have the sol der fl ow along with the copper. Do not try to work
f as t as the h eat m ust fl o w ahead of the sol de r an d this takes time. D o n o t run
back an d f orth over the j oin t b u t m ove in on e direction . When the join t i s
. sol dered d o n o t m ov e i t t o o soon b u t wait f o r the sol der to set. Unnecessary
sol der m ay be wiped off with a cl oth af ter heating a surf ace, but this sho ul d n o t
be a common practice.
Re-tinning the Copper.

If f o r an y reason the copper n eeds a n ew coat of tin you m ust rem ove
the black surf ace with a file or g rin ding wheel . Af ter you g e t i t sm ooth heat
it n e a rl y t o the p oin t where it beg in s t o show red. R ub on a sof t brick or a
bl ock of sal- amm on i ac to cl ean i t an d then p u t a l i ttl e sol der on the block an d
w o r k the tin in to each of the f our surf aces. T h i s m akes the poin t l o o k b rig h t
an d shin y l i ke n ew tin. Y our soldering copper m ust be kept in this con di t i on
t o work well .
Page Ten
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SHEET METAL PATTERN DRAFTING
Sheet m etal pattern draft i ng is m a inl y an appl ication of the principles of
devel opments and i n tersections as they are g iven in the usual courses in M e
chanical Drawing i n h ig h school s . I n a d di ti o n the sheet m etal worker uses a
g re a t m an y short cuts, some of which are n o t strictl y according to the rules of
projecti o n . B u t t h e pupil w h o l ays o u t h i s patterns according to rul e will n o t g o
wrong prov i di ng he m akes proper all owances f o r seam s , f ol ds, w i ri ng , etc. S i n ce
most of the articl es m ade of sheet m etal are i n the f o rm of cyl i n ders, p rism s ,
cones or pyram i ds, or parts of these sol i ds , i t will b e well f o r t h e pupil w h o ex
pects to l ay out h i s own patterns to study the f orms of these sol i ds a n d of their
i n tersections with each o ther. So far as p ossible each p upil shoul d l earn t o
devel o p h i s p atterns o n p aper a n d test them o u t i n m etal , b u t i n order t o sav e
m aterial the i nstructor sho ul d check all resul ts with a m aster pattern. Since
patterns m ade without proper all owances and without fi x i ng the siz e , shape an d
l ocation of notches are usel ess, p articul a r attention m ust be paid to these details.
R ul es f o r these all owance s are g iven in another parag raph .
Allowances for Seams and Wiring.

I n an ordin ary l ock seam three times the wi dth of the seam m us t be added
to the edges bef ore f ol ding . Littl e attention is paid to the am ount added on
account of the thickness of the m etal but where heavy m etal is used this has to
be consi dered.
T h e all owance f o r wiring is usually twice the diameter of the wire plus
twice the thickness of the m etal , but experience in this case is a better guide
than the rule, a s it is hard to set the machines so that an exact amount will be
turned on the edge of the m aterial .
Page Eleven
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Qf:
' XT9)
QEXT9)
P.S'&W.CIL
lls ...w.c
.
Blowhorn Stake
Beakhorn Stake
QOO)
p.s.&w,
Hollow Mandrel Stake
Candlemold Stake
QEXT
P.s. w.c.
Double Seaming Stake
Conductor Stake
Creasing Stake
Square Stake
Hatchet Stake
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Burring Machine
Beading Machine
Setting Down Machine
Turning Machine
Wiring Machine
Forming Machine
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Moores Double Seaming Machine
Cornice Brake
Squaring Machine
Groover
Folding Machine
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SHEET METAL. JOIIVTS

LAP
JOINT
sox
1 J"N, ,
vO/NT
CO VNTRSIINI(
ED6-QVIRJOINT
RIVETED
I.
CASH
BOX
oVT6rD G/fOOVED
814111.
JOINT
.JOINT
1I'ZIZZZ!l=ZZ
01100 VED JOINT
INSIDe'
GROOVED
$AM
DOVSLI" SEAMED
BOTTOH
INSTRUCTIONS AND OPERATIONS.

Plate I.
I.
2.
3.
Sheet Metal Joints and Seams.
Study these diag ram s carefully. Learn the names o f the jo i n ts and b e able
to describe each with a sketch .
No te that the p ropo rtio ns o f these jo i n t!? and seams m ust v ary som ewh at
with the thickness o f the m etal . No te al so that they m ay need sol der to
hol d the p ieces tog ether.
Why i s a g roov ec! seam called a lo ck seam? What i s the use o f the hem an d
the do uble hem?
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FOL.DING, WIAING AND RIVETING

EXERCISE.$'
SINGLE HEM
FOLDED seAM
-
..
Dt:JUBL.E HEM
...oe
e---
-------
W/AED
EDGE
14>j--2.
WIRED
3.
4.
I.
2.
3.
4.
5.
6.
8 "--------i
#: /4 WIRE
--1-0;--2.
EDSE
Plate ll.
I.
2.
-*,
Exercises in Folding, Grooving and Wiring.
(First Exercise.)
Cut two p ieces o f sc rap tin 1 Yz by 8 inches in size.
With the folder set for a Va inch sharp fold both edges of each piece. C are
fully f latten down one edge o f each piece with a mallet on a flat surface.
Hook the other two edges together and groove the seam with the proper
grooving wheel on the machine.
Fold one edge of this exercise over a second time to make a double hem.
(Secon d Exercise.)
Cut two pieces o f galvanized i ron IY4 by 8 inches.
Mark a line with the scriber l4 inch from the edge o f each piece and lay
off four points as indicated, m arking the points with the pric k p unch .
P unch these holes carefully using the machine or a soli d p unch on the end
o f a bloc k o f wood.
Using 12 oz. tinned rivets fasten these pieces together c arefully. Use a
ligh t rivetin g hammer an d try t o form a rounded head on the rivet. Finish
the heads with a rivet set.
P repare the edges of this exercise for wiring by using the folder set to 3- 16
inch with the table set for an open fold.
Cut two piec es o f 14 guage wire eight inches long.
Wire these in place
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<lirpded bv the instru-ctor.
n",
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FOOT SCRAPER$.
2.-1,."
RIVT
"
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2
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t
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lib,
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Plate III.
I.
2.
3.
4.
Foot Scrapers.
Ch oose one o f these designs. Cut stock from blac k i ron, 20 gauge o r thic k
er and 3Yz by 5Yz inches in size.
Round all corners by marking with chalk and laying off a radius with di
viders. Cut and file to shape.
P unch VB inch holes for rivets on machine after carefully layi ng them off
with steel rule. Bend pieces over a form in the cornice bra ke. Rivet with
one-p ound round head ri vets.
Punch holes for sc rews Yz inch from edge and fasten to doorstep.
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COOKIE CurTER
- ,
I
I
I
Plate IV.
8f--1
Cookie Cutter.
l.
Cut stock of IC tin to dimensions given.

2. Mark o ff allowances for wiring on larger piec e, cut corner and wire with 16
gauge wi re.
3. Run the body through the forming machine with the wired side down .
4. Lap the en ds j ust Va inch an d hold with pliers while tac king with solder.
Finish soldering after showing to the instructor.
P repare handle by wiring in the flat an d forming in the machine. C rease
5.
ends in the stake or by using the turning machine. Solder in place after
c arefully fittin g each en d to the bo dy. Remember that no j oint should be
soldered un til the surfaces fit closely together at all points.
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Ii
" I
:E
I
I
I
I
,
I
I
I
i1 II
1 I
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/1 11
PATTERN:
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..: ::. :.. -...:; -.: -= =- -.::J 'C"::' -_-"/_ -+_-L__
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Plate V.
oVSLE HEM
,
,
"
J.
Match Safe.
I.
Cut three pieces to dimensions given. Scribe J ines on edges VB inch from
edges an d then VB inch from these lines. Clip corners as indicated an d lay
o ff and cut design at the top.
2.
Fold double hem where marked. Bend three edges of each en d in folder
at right angles. Fold two long edges of main pattern VB inch from edge
an d p lace VB inch strip of sc rap metal un der each.
3.
Ben d main pattern on fi rst an d sec on d dotted lines. Remove st rips of metal
and slip en ds in place. Doub le seam the en ds over a stake or b loc k of hard
wood. Fold remaining edges toward the b ac k with pliers.
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SUGAR scoop
- ----- ------14----4*':...
'
oiJ
--- - - -- -- - - - - _
-----
OQ
HANDLE
r---
!
HALF PATTERN
====
Plate VI.
I.
2.
3.
4.
Sugar Scoop.
This sc oop is to be made o f I C tin with bac k to be snapped on the body and
soldered as indic ated. The h andle is to have wired edges.
Use pattern to lay out body of sc oop. Cut a p iece for the back on the cir
c ular shear and burr the edge Va inch as indicated.
Form the body to the required shape and snap inside o f bac k. Tac k c are
fully in place with solder at several points, finally soldering Va inch lap at
the top. Solder back on the in side. Be c areful not to overheat the j oint at
the lap.
Wire the edges o f h an dle. Form to shape in machine using your hands to
bend the h an dle around the roll. Solde r handle on the bac k after caref ully
fittin g in place.
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II
2_
t1L
l-
4r- t-'-
!7
IG
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M
o 1
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P A7 TE. Rlt
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r_
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Co
- -yl
-
FOUR PIECEELBOW.
Plate VII.
2-
f-'
i"""""ooo
3
.,.
.s-
f>
M
U
Four Piece Elbow.
I.
Decide on the dimensions o f the elbow wanted. Lay out a set o f patterns
and string them together with strips o f metal. Use the stan dard method
given to lay out this set. Be sure to add to each pattern the allowances
for seams on all sides where necessary.
2 . Use the elbow edging roll an d the burring machine according to instruc
tions. Slip parts in place an d tack with solder. See that the elbow is not
twisted before comp leting the sol dering.
3. Use a similar method i f an elbow with three or five or more parts is wanted.
The throat, OH, is about one-half the diameter o f the p ipe, but may be in
creased.
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BREAD
.PAN.,
['\.
"
'\.
I,-"IIf--- 6f/
--
Plate VIII.
Bread Tin.
t.
This pan is o f t h e st andard const ruct i o n with eq ual t aperi n g sides and sol id
corners, It m a y be m ad e easier t o const ruct b y cutt i n g away p art o f ea9 h
corner. I n this case the pan will n ot b e water t i ght b ut will serve v ery well
f or a b akin g t i n .
2.
If the solid p an is wanted, cut out the patt ern as m arked and form the cor
ners over a hat chet st ake. T h e n t urn t h e sides and ends over a bl ock o f
hard wood cut j ust the shape o f t h e inside o f t h e p a n . U se the h at chet
st ak e and th e m al let t o cl ose over t h e f laps b ut watch carefull y t o see t h at
heavy bl ows are n ot used and t h at each corn e r is b e nt exactl y o n t h e li n es.
A pair o f wide n osed p liers m ay b e used t o help t urn t h e fl aps.
3.
T h e wiring m ay b e d one by b e nd in g the ed ge o f t h e sheet over t h e h at chet

st ake, and t ucki n g t h e wire in pla ce wit h t h e m all et and t h e wiring m ach ine.
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,fCH/CK
I
j./!;
[I
I
I
"0
"
,
,
"
(0
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1-/2-
10
4.
5.
6.
---
,
,
P
AL
f/
I
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OQ
--
"
FRONT
a
-- - - - -
----
Plate IX.
2.
3.
Ii;,.-
',
>-J---
,0
1.
PATTER
\
\
,
,
I'
\ 3-
FEEDER,
(
I
,
LID
I
,
"
0
- -.
I"
",til
M
I
,
'i-
//{' 2+/r-: -:"
Chick Feeder.
Cut one piece o f 39 guage galvan ized stoc k thirteen and one-half i nches
sq uare. Cut another piece six i nches by eight i nches for the front and one
4 % by BYs inches fo r the lid.
Lay off all these pieces acc ording to the drawing and cut to size and shape.
F ol d main pattern to shape and rivet the bottom i n place with 12 oz. rivets.
One-half o f the rivet holes may be punched before ben ding to p osition.
Rivet the front i n place on the dotted line shown in the drawing.
Form the metal for the hin ges and slip in a piece of N o . 10 wire to fo rm the
hinge.
Attach the lid after folding the edges at right an gles.
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OUST PAN
r
PJate X.
#10
WIRE
-
--
Dust Pan.
I.
Cut stock from 28 guage galvanized iron or from blac k stove pipe iron. Cut
one piece lOy,. by 14 inches an d one 5 by 5 inches.
2. Lay off lines as in dic ated. Cut notches, clip corners an d cut diagonal cuts
Run beadin g wheel over
for foldin g. Fol d VB inch hem on three sides.
c urved line to start bend.
3. Turn edge for wirin g settin g folder V4 inch. Fold corners an d prepare wire
for wiring. Bend wire in vise to get sharp bend 1 Yz inches from each en d.
Wire the edge as directed by the instructor an d solder the ends in p lace
using aci d flux.
4. P repare h andle with loc k seam an d set in place through cuts marked in
b ac k as in dicated. Hold h an dle firmly in place an d turn fl aps inward an d
solder down. If desired these flaps may be covered with a circ ular p iece
of metal soldered down. A n arrow collar may al so be soldered around the
outside, where the handle joins the pitn. A c ap should be cut to fit the han
dle and soldered in place.
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CANTEEN
--
c:!I::il
.i:i /1:.
!
.cJir
-
2
"
':f
"I ;*"
Jif"1 !!
IU$
.
_--.
NOTEf- THE WIPTI/

8t: C HAiVGD TO SUIT.
m
mu
Plate XI.
;/
"-,
-,
..,;.1:._
THIS BAND NAY

------
I
/
'I
.
2. OF THIS
_______________
;4-;.;;-
-- -
./ '\
/z
___________ _ _____
:-...
"8uYr.
{
--L
1'4
__
Canteen.
I.
Cut two si des on the circ ular shear and burr the edges Va inch. Cut a band
of tin o f the desired width an d fold both edges and flatten down in the brake
with a inch strip o f 24 guage blac k i ron un der the edges. With the hollow
chisel c u t a semici rcle from each en d about one inch in diameter.
2 . Form the b an d into a circle on the former and remove the strips o f i ron
c arefully with a pai r of pliers. Slip one o f the si des c arefully in place and
tac k wi th solder. Finish soldering an d see that a very neat an d smooth job
is done.
3. Slip second side in place an d press out with a rod of wood introduc ed'
through the opening. See that it comes into place n icely before soldering as
you di d the first side.
4. Cut three strips o f scrap tin Vs inch wide and fold a double hem in each edge.
Ben d these to the shape sh own an d solder in place on the outside as in the
drawing. Solder on a sc rew c ap taken from a c an or purchased from a deal
er.
5. The sides o f th is c anteen may be p added and the outside covered wi th cloth
or imitation leather if desired.
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PINT TIN cup
,
I
,
,
WIRE
n
.
:
-A
'"'J
------------
FOR
4.
5.
6.
7.
8.
"
BOOY
I
,
:
:t '
'I,,:
:
: :
,
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' ....,.,.,.,
.. ' '
____
:
I
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II 7/"
Plate XII.
3.
. .
_____
- - -- - - - - - -
I.
2.
,.
"
3f1
PATTERN
_-_-_t
-,-_
- -_=_-_
"'"
___
__
One Pint Tin Cup.
Cut three pieces o f I C tin accordin g to the dimensions given .

Burr the edge o f the bottom with the burring attachment on the circular
shear.
P repare the en ds of the long piece for a loc k seam after carefully notching
the c orners.
Wire the top edge of this piece with 14 guage wi re. Form into a cylin der
bein g careful not to spoil the fold for the seam.
Finish the loc k seam and solder on the insi de.
Burr the bottom edge on the burring machine and slip on the bo ttom . Turn
the edge of the b ottom c arefully over the edge of the body with a hammer
an,] fasten with a setting down machine. If a double seaming machine is
available it should be used at this poin t. I f not, do the best you c an with the
mallet and the stake.
Solder seam on the in side.
M ake the han dle as you did the h andle for the sugar scoop and solner it in
place over the seam.
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QUART
MEASURE
&A!..Vlf/\N ZED IIPOIII
Dh4HTER
S--fi'
t=;;;t::=:::::
I
_.
___
--t' ''''
I
I
---
14if --\_
________________
___ _______
Plate XIII.
1.
-1
----
BOTTOM
BVRH""
_____
---
I'
OF
___
-,.
-,.
--
-------
'-
__
---- ---'
Quart Dry Measure.
This measure m ay be made o f 30 guage galvanized iron . It is calculated to

h old 58 cubic inches. The instructions for making i t are the same as for
the tin cup, except for the h an dle.
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WA TR
PA/'1.--1 7J- - -
_
___
- - - - -
- -
/
I
I
/
/.
- - - - -- -
, J
.l " --I ----'1'..-
__
Plate XIV.
Water Pail.
I.
Cut two p ieces j ust alike for the body o f the pail. Double seam these to
gether on one edge and form to shape of pail and double seam again. Solder
the inside o f the seams carefully after grooving.
2 . Wire the top edge with No. 9 wire with the joint i n the wire, at one o f the
seams.
3. D ouble seam the bottom as in other exercises, and solder inside .
4. Rivet on two m alleable ears and form a b ai l out o f No. 6 wire and fasten i n
place.
N ote :-Other sizes of p ai ls m ay be worked out in the same way. Use galvanized
sheets not li ghter than the 2 7 guage for a durable pail.
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F UIVNEL
..
t."\
'\
- -
B OO Y
A i---4-..-
-- - - - -
L /" J
,2-,; ,
PATTERN FOR
- -
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RI,vGr--f1
O
#'/4 Wlr e.
CU P
FO R
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r-
Plate XV. . . Funnel.

t.
2.
3.
4.
5.
Lay out parts from patterns or make patterns from stiff paper in drawing
room and submit to your teacher for inspection. Notice that the drawing
gives the method generally followed in layin g out any funnel pattern.
Fold two straight edges o f body i n opposite directions and form to shape
with your h an ds over a funnel stake. Groove the seam with a hand groover
and solder inside.
Turn the edge for wirin g on the turning machi ne. Form the wire and fasten
it in place with a mallet. Finish wiring on the mach ine.
The sp out m ay be made with a lap seam or with a lock seam. In either case
it should be I}eatly soldered in place outside of the body of the funnel.
Form the ring to shape with pliers and h ammer, and solder clip in place
just un der the wire over the seam .
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GA S OL I N E:
F VNNL
. ;:.:--===---..:.....: ---
--
PA T TERN
FOR eoOy
HALF
ELEVTIO/v
'.,
"0
\
\
eA I'IJ:J
'-- -
----- - - -
Plate XVI.
1.
2.
3.
- -
Fo /'f
T op
\\\\: - - --
'l'
:f
-- - f
:
- -- -
Gasoline Funnel.
Follow i nstructions for small funnel except for top. Instead of wiring this
edge make a band of metal one edge of which is wi red in the flat.
Form this band into a ring which is Ys inch less in di ameter than the di
ameter of the unfin ished funnel. Solder the lock seam.
Burr an edge on the band and with the elbow edging rolls turn a V shaped
groove on the i nside edge of the funnel and double seam. I t should not
be necessary to solder this joint. A second band may be made to slip inside
this funnel to hold a piece of chamois skin in place, if desired.
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------
3"
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1_.5.
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Plate XVII.
I.
2.
3.
- -
Utility Measure.
6#
--
--I
T h i s may b e used a s a measure and fun nel combi ned or a s common b ottl e
fill er.
...
Cut the four pieces of stock as d irected i n the d rawing.
Form the b od y and sold er the side seam o n t h e insid e .
and burr the bottom ed ge to receive the bottom.
W i re the top ed ge
4.
D ou bl e seam the bottom i n place.
S.
T urn a hem o n t h e curv ed ed ge o f the h ood w i th the b urri n g mach i n e and

flatten w i th mall et.
6.
Form the h o od to shape and sold er the l ap sea m . T u rn a groove in the ed ges
which are to fi t on the top ed ge of the m easure with the smal l turner. Sol
d e r the h o od in place begi n n i n g at the back and fi tting the j o i n t careful ly .
7.
S old er the h andl e and the spout in place.
S old er insid e .
T h e hand l e should fi t over the
seam.
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rlSHING TAC KL E BOX

.
-,\
' 'N--
or..!-
CORNER '
OF TOP
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Plate XVIII.
:s "
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BEAD
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=,, .
Fishing Tackle Box.
1.
Cut stock for sides and ends i n one piece, 41'4 by 26 9- 16 i nches. Lay o ff
bends carefully with try square. Cut n otches i n lower edge a n d at corners.
Turn :.l % i nch hem a t the top edge. Turn a loose hem in bottom edge an d
roll a bead j ust below the hem in the upper edge. This bead will stiffen the
bo:< and serve as a stop for the lid.
2.
Form a cash b o x j o i n t i n the ends and ben d sides and e n ds to meet..

this j o i n t neatly a n d solder inside.
3.
Make the top l i ke a pan with corners folded over and fastened down on the
outside a n d with a wired edge.
4.
Cut two p i eces of tin for the h i n ges and a fter ben ding them aroun d the
w i re slip through slits cut in the b o x j ust above the bead and solder down o n
o n t h e insid e.
Design a clasp for the box and fasten in place.
S.
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Fit
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r-
BREA/)
- - - - - - - - - - - - - -- - - ..,
B
FRON TANLJ BACK

B
ii
BOX
.... - - - -
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Plate XIX.
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Bread Box.
This box requires quite a large amount of material and should not b e at
tempted by p upils who are careless. I t sh ould be made of good tin p late,
heavier than that used for most exercises. When finished it m ay be enameled
and nicely finished for use.
2 . Cut the six pieces o f stock as dimensioned. Allow for joints a t all corners
the amo unt m arke d. Also allow for wiring the edge of the cover.
3. Turn all edges m arked " A" at right angles, setting the folder a t 3- 16 inch .
Turn all edges m arked B all the way over with the same settin g, but do
not flatten down. Turn a double h em at the top.
4. Fasten the front and back and ends together by double seami ng. It will
not be nec essa ry to sold er.
5. Set the bottom i n place and double seam over a square stake.
6. The top is a simple pan with a wired edge which may be h in ged i n p lace i n
seve ral way s. It shou ld not fi t too tigh tly.
in place on the ends and a clasp m ay be design ed
7 . Handl es may be soldered
and use d to hol d the lid in pla ce.
1.
"
"
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HEX A G ONAL VA SE
Plate XX.
Hexagonal Vase.
I.
This vase may b e m ade o f t i n plate, galvanized iron or zinc.

sh ould first be worked out on paper and tested for accuracy.
2.
Cut six pieces from the stand ard p attern.

terial which has an angle o f 120 degrees.
3.
Begin bending the strips near the middle, usin g the cornice brake w i th
curved wooden forms to secure the p roper curvature.
When all the p arts have been bent as n early the correct form a s p ossible,
begin solde rin g them together, usi n g the template to test the interior an gls.
Tack the p arts at imp ortant i ntersections first and see that the vase d o es n o t
get twis ted i n b uilding i t u p . Great care. shoul b e taken t o see that the
strips are carefully fitted to gether b e fore solderi n g . All the solde ri n g can
be do ne fro m the ins ide .
A bott om and a false bottom can be soldered in p lace when the vase i s c o m
4.
s.
The p attern
Cut a template f r o m scrap m a
ple ted .
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Cornell University Library

WITH NOTES ON EQUIPMENT, MATERIALS

Director Vocational Education

PRINTED ON THE HIGH SCHOOL PRESS