V.

Barrel Bolt
INTRODUCTION
Barrel bolt is primarily used for locks to doors, cabinets, gates and others
to provide safety for people and some important things. Making a barrel bolt is
not that easy because it requires special machine tools like the milling machine,
lathe machine and some tools that can only be found in a work shop. Moreover,
the person that would want to make such item should know how to basically use
the machines and tools mentioned earlier. This kind of project can be easily done
in the engineering shop.
OBJECTIVES
At the end of this barrel bolt exercise, students should be able to:
1.
2.
3.
4.

Correctly and accurately measure dimensions in a metal

Learn the importance of using the center punch before drilling
Perform the drilling process easily
Know how to operate the lathe machine, drill press, power hack saw and
vertical milling machine
5. Learn how to weld and its safety measures
MATERIALS AND METHODOLOGY
Materials and Tools:
Steel Ruler
Center Punch
Welding Rod
Try Square
Concrete Nail

Round Bar
Flat Bar
File
Spandrel
Hammer

Machines:
Drill Press
Lathe Machine

Vertical Milling Machine

Power Hack Saw

Methodology:
1. Cut a flat bar with a length of 190 mm. With a flat bar at hand, mark it
using the steel ruler and concrete nail by following the dimensions shown
in Figure 1.

2. Create shallow holes on the points using the hammer and center punch
before drilling. This will make the drilling of the holes accurately and
easier.
3. Using the drill press, drill the shallow points on the flat bar where the
center punch was marked. A 5mm drill bit was used to drill the holes. The
appearance of the flat bar after drilling is shown on Figure 2.
4. Using the vertical milling machine, mill apart the second middle hole on
the left as shown in Figure 3. Milling was done two times to the flat bar to
create that long straight hole.
5. Using the vise, hammer the two edges on the left part of Figure 1 to 90
degrees. Cut the 25 mm of the upper left part of the flat bar shown in
Figure 1. File the edges afterwards to remove the sharp edges.
6. To create the part where the bolt will be placed, a lathe machine is to be
operated and three pieces of diameter X 3 round bars was created.
The round bars are drilled which is shown on Figure 4.
7. To create the bolt, cut a round bar with dimension 5/16 diameter X 10.
Grind the edges of the round bar to avoid sharp edges. Hammer the round
bar in a vise to create its handle
8. To join the flat bar and the round bars together, welding will be done. The
3 small round bars and the long round bar was positioned and attached in
the flat bar using a clamp. The connecting sides of the 3 small round bars
and the flat bar are then welded as shown in Figure 5.
9. After welding, the overall barrel bolt is filed once more then painted. The
final product is shown in Figure 6.
BILL OF MATERIALS
Seq.
No.
1
2
3
4

Item
Flat Bar
Round Bar
Round Bar
Welding rod

FINISHED PROJECT

Description
3/16X1 X10
5/16 diameter X 10
diameter X 3
Nihonweld N-44A E6013

Quantity
1
1
3
1
TOTAL COST

Unit Cost
(PHP)
100/bar
100/bar
100/bar
30/kg
330

Figure 1. Dimension Guide for Making Barrel Bolt

Figure 2. Appearance of the Flat Bar after the Drilling Process

Figure 3. Milling the Flat Bar to make the Hole at the Right

Figure 4. The creation of three diameter X 3 round bars in the lathe

machine.

Figure 5. Welding the three diameter X 3 round bars to the Flat Bar

Figure 6. Barrel Bolt Final Appearance

ENGINEERING DRAWINGS