Final proposal

Introduction to Production Techniques - THTR 1320 - Final Project – Second Round

1) Proposal (50 points possible) This is a typed description of the item to be constructed. It must include the following:

a)    Description of the item. This should be a clear and concise description of the item and its use.

I will construct a bench to sit on with no back or arm rests. The seat will have a height of 16 3/4 inches and the seat will be 16 inches deep. The bench will be 4 feet wide. The bench will be a combination of 16 gage 2 inch square tubing and wood. The bench will have 2 support beams on either side (12 inches) and one 44-inch support beam connecting them. On each 12-inch support beam the letters X B E will be welded on. The letters will be made from a steal sheet. The letters will be 6 inches tall and 4 inches wide and will sit on top of the support beam. The metal will be painted maroon and the letters either black or white. The bench will have 6, 4’ x 1” x 2.5” mahogany pieces that will be screwed in thanks to a tap and die.

b)    Types of materials that it will be constructed from. Part of your research should be consideration of which materials you will use in the construction of the project.

·      2 inch 16 gage square tubing (Need 21’)

·      24 1.5” brass screws

·      Paint

·      Six 4’ x 1” x 2.5” Mahogany

·      1’ x 2’ steal sheet

c)    Construction methods and techniques that will be employed. Consider and explain how you will build the project.

First I will cut the metal into 48-inch sections. I will take 2 of these and mark at 16”, using the band saw I will cut 45° angle so that there is a 90° cut out and one side is not cut. I will do this 3 more times and bend the metal into a U shape and weld together. I will then weld on the 12” support beams to both us. I will then tack weld on the 44” seat tops and then flip over and tack weld on the support beam. I will then go over and weld on completely. I will then tack weld on the letters XBE on either side. I will sand and finish all of the wood. I will drill the 24 holes needed to screw in the wood and using the wood center finder to mark the wood. Then the bench will be painted. After the bench is painted I will need to tap the holes and screw the wood to the metal frame. I chose to have the majority of the seat made from wood and not metal because wood has some bend to it and will be more comfortable to sit on. 

d)    Sketches, drawings, etc. explain the item. These are not the final drawings. They should help to communicate and explain your project.

(Sorry these lines are so sloppy I was drawing them on a train)

e) A "production" schedule that details how you will meet your deadline. This should help you understand the time that you will need to finish the project. Do not underestimate the time this will take.

Before I do anything I need to practice welding because my experience is very limited and it has been almost 2 years since I have done it. So a few days of practicing welds on scrap metal (ESP. at 90° angles, something I really struggled with before). While in the shop working on this I will also set up all the materials I will be using. This means cutting the wood and metal pieces to the correct size and making sure all the tools I need to use (brass screws, center finder, tap and die, etc.) are available and in the shop. – 3 days (~8 hours total)

Once everything is set up and I have practiced welding I think the project will be able to come together rather quickly. I will spend about an hour doing the cut outs to make the U and welding the cut outs– 1 hour

I will spend 30 minutes welding on the 12” support beams – 30 min

I will spend 30 minutes setting up the tack welds for the support beam and seat, and another 30 minutes doing said welds. (1 hour)

I want to give myself an hour to go over and grind down welds that may have come out poorly – 1 hour

After the main structure of the bench is complete I will need to drill holes in the wood and sand and finish with oil the mahogany so that it only needs to be screwed into the metal. – 3 hours

I will paint the metal frame and the letters now. - 1 hour

I will tap the drilled holes to act like a bolt – 1 hour

I will screw the wood to the metal and the seat will be finished. – 1 hour

Total time: 19.5 hours

f) A detailed list of the materials needed to construct the item. Be specific- ½” plywood or 1x4 does not provide enough information. After deciding on what materials you will use, consider what you will need to order to complete the project.

·      One 24’ piece of 2 inch 16 gage square tubing (Need 21’)

·      Wire feed welder

·      Metal grinder

·      Tap and die

·      24 1.5” brass screws

·      Paint

·      Six 4’ x 1” x 2.5” Mahogany

·      Sand paper - various

·      Teak oil or tong oil or linseed oil

·      Cordless drill

·      Wood center finder

·      Steal sheet 1’ x 2'
`   band saw

g) A price list for the materials and hardware needed to construct the item. Part of any project is budgeting. You need to find prices for your proposed materials. DO NOT assume you can find this information on the Internet.

·      One 24’ piece of 2 inch 16 gage square tubing – $48.00

·      12 x 2 pack 1.5” brass screws – $14.88

·      2 X Mahogany 3/4” x 8” x 48” - $89.98

·      Cost of paint (2 cans) - $7.74

·      1’ x 2’ metal sheet - $16.09

Total cost: $172.72