The Workshop
Books reviewed in this section
Tools and techniques for small workshops are the subjects of this chapter. The use of tools, and the ability to make them using local resources and equipment, are certainly very important in any appropriate technology effort. In some areas where small blacksmith shops, foundries, woodworking or machine tool workshops exist, many of the tools and processes covered in these books may have been in use for many years. In other areas, most of these crafts and skills are unknown. Therefore, the tools found in this section are of many different types, from simple
hand tools to wood-turning lathes to metalworking equipment. Some may be made at the village level, others may require metalworking shop facilities.
The first several books offer illustrated inventories of a great variety of tools. Other books describe the proper uses of a wide range of hand tools and machine tools for both wood and metal work. The crafts and skills covered include woodworking, blacksmithing, general metalworking, forging and casting, sharpening, sheet metal working, designing bearings and springs, working with metal tubing and copper piping, and others. There are also plans for workshop equipment: lightweight power tools, sheet metal bending tools, and more.
These reference books, containing thousands of ideas, should be valuable to an appropriate technology group in its own workshop. They are also a source of learning materials for improving skills, increasing versatility, and expanding available tools and equipment among local craftspeople. It should be remembered that many workshop crafts, such as blacksmithing, cannot be easily learned from a book; these reference materials can only supplement skilled instructors. However, even the most experienced blacksmith will find many unusual and valuable ideas in a reference such as Practical Blacksmithing.
Tools and How to Use Them: An Illustrated Encyclopedia, Available in the AT Library. INDEX CODE MF 04-122, paperback book, 352 pages, by Albert Jackson and David Day, 1978, $13.95 from Alfred A. Knopf, Inc., 400 Hahn Road, Westminster, Maryland 21157, USA. Available in the AT Library
This beautifully illustrated book is the best one available for descriptions of the wide range of useful hand woodworking tools. It also covers a few gardening tools, power tools, plumbing tools, and includes more than 1500 excellent drawings. For each tool the authors list other commonly used names, size, the material it is made from, and its purpose; this is followed by a short but valuable description of how it is used. Most of these tools originated in Europe or North America, but many are in common use all over the world. A good source of ideas for local adaptation.
Highly recommended.
Tools and Their Uses, Available in the AT Library. INDEX CODE MF 04-123, book, 186 pages, by the U.S. Navy Bureau of NavalPersonnel, 1973, $4.50 from Dover Publications, Inc., 31 East 2nd Street Mineola, New York 11501, USA. Available in the AT Library.
 15% of each order supports Village Earth.
This book covers a very wide selection of common hand and power tools. The purpose is to "identify tools and fastening devices by their correct names; cite the specific purposes and uses of each tool; describe the correct operation, care and maintenance required to keep the tools in proper operating condition, and finally perform accurate measurements." This book will not substitute for books covering in detail the techniques and equipment used in woodworking and soldering, for example. It is just a general introduction, but one that would be useful to any workshop education program using common tools. Safety information is included throughout.
Basic Machines and How They Work, Available in the AT Library. INDEX CODE MF 04-81, book, 161 pages, prepared by the U.S. Navy Bureau of Naval Personnel, 1971, $4.50 from Dover Publications 31 East 2nd Street, Mineola, New York 11501, USA. Available in the AT Library
Written as a reference manual for sailors in the U.S. Navy, this book explains basic mechanical principles and their applications in simple and complex machines. Illustrated examples are used to show how these principles work in common devices. For example, oars, wheelbarrows, handpump handles, and the block and tackle are forms of the lever; the brace and bit, wrench, and winch are forms of the wheel and axle. Many of the examples include explanations of how mechanical advantage is obtained, and how to calculate that advantage using simple arithmetic.
Later chapters explain the uses and combinations of basic machine elements (like bearings, linkages, cams) in machines such as the typewriter and automobile engine. Useful as a reference and as a practical way to study the physics of mechanical devices. Slang and sailing terminology may sometimes be difficult for the non-native speaker of English.
Equipment for Rural Workshops, Available in the AT Library. INDEX CODE MF 04-92, book, 94 pages, by John Boyd, 1978, £5.95 from ITDG; also available from TOOL. Available in the AT Library.
15% of each order supports Village Earth.
This book "is intended to help people choose appropriate tools and equipment. It is not an instructional textbook on workshop technology." Shows workshop building layout and basic sets of tools (primarily hand tools) for 1-6 person workshops, with and without power supply, for woodworking or metalworking. The simplest level of powered equipment requires an electric drill with attachments to convert it into a circular saw, grinding wheel, jig saw, and power hacksaw. Machine tools are shown for the larger, powered, 4-6 person workshops. The author notes that "the hand tools in the lists of basic equipment can be used to do the same work as the much more costly power tools.... Power tools only speed up the work and are not economic unless there is enough work to keep them in use for a substantial part of each day." Includes mid-1977 prices of tools. Lists suppliers in Asia/Africa/Latin America. Many illustrations and photos.
Shop Tactics, Available in the AT Library. INDEX CODE MF 04-118, book, 114 pages, by B. Abler, 1973, Running Press, out of print. Available in the AT Library
"Shop Tactics is a guide to tools, materials, and procedures that are within the reach of a small basement shop. The beginner and amateur (and low-budget) tinkerer, artist or scientist will find here plenty of information to see him through almost any project he can undertake, whether simple or complex. Because Shop Tactics begins with simple tools and materials (hammer, nails, wood, file, drill, saw, and wrench) the beginner can use it as an introduction to manual techniques. He will find step-by-step instruction leading him through the motions for using these and other basic tools and materials."
"After familiarizing you with basics, this book describes the use of abrasives, adhesives (solder, glues), plastics (plexiglass, epoxy), and finally molds and casting. The last chapter concerns efficiency and effectiveness in the use of manual techniques. An appendix of basic devices, a bibliography and an index are included.
"The description for each tool and material is presented with concrete examples (the section on sheet metal describes how to make a ring) so that when you work through the example to learn the procedures you will have a completed piece of work. But this is not a how-to book presenting instructions for the completion of a few projects; instead it gives you skill and insight into tools and materials so that you can plan and complete your own projects. The home tinkerer who wants to build a mold, or the scientist who wants to build a specialized gas burner will all find here not specific instructions, but plenty of information to guide the project to completion."
This book is "directed at your imagination in the hope that, when you know what is already known, you will be able to think of new things (that you would never have been able to think of otherwise) by recombining processes and extending materials to satisfy each new demand you make of them."
Illustrations (literally hundreds of them) are included to accompany each step in the text and ensure that the text will he understood by any reader. Each presentation is very clear and easily understandable. In particular, there is a valuable discussion of a variety of casting methods. The "Devices" section gives illustrations and simple explanations of 12 simple devices (solar still, bicycle sprocket drive, set screw).
This is an excellent book, both because of the clarity of presentation of the material, and the regular use of illustrations. Perhaps of greatest value is that the author seeks to develop basic skills and an experimental approach that is fundamental to future development of appropriate technology devices.
The Use of Hand Woodworking Tools, Available in the AT Library. INDEX CODE MF 04-125, book, 273 pages, by Leo McDonnel and Alson Kaumeheiwa, 1978, Delmar Publishers, New York, out of print. Available in the AT Library.
15% of each order supports Village Earth.
This introductory book presents only the basic hand tools used in carpentry, and most of the book is devoted to explaining how to properly use them. No previous knowledge is assumed. Designed for use in teaching, the book contains questions at the end of each section.
The author begins with measuring tools (from the T-square to the builder's transit level—the only rather complicated tool presented), and continues with saws, planes, edge cutting tools, and boring tools. Sharpening is discussed in detail for each of the cutting tools. Also covered are nails, screws, and dowels. Well-illustrated.
Handtool Handbook for Woodworking, Available in the AT Library. INDEX CODE MF 04-97, book, 184 pages, by R.J. DeCristoforo, 1977, out of print in 1985. Available in the AT Library.
This book shows how to use woodworking tools commonly found around the world. These include measuring devices, saws, hammers, drills, screwdrivers, chisels and planes. The author also discusses safety, sharpening, shop math and how to choose good tools.
"You won't find this (a crown) on all saws, but many experts look for it as an indication of careful designing and superior quality. A crowned saw is one where the silhouette of the toothed edge shows a gentle arc rather than a straight line from the heel to the toe. The reason for the shape is to obtain maximum cutting effect with minimum drag. The arc brings fewer teeth into contact with the wood fibers. While you don't have as many teeth in full contact, those that are cut deeper, faster, and easier."
This book is full of tricks and tips for woodworkers, and the 400 illustrations make it easy to understand. Safety measures are very well-covered.
Woodwork Joints, book, 176 pages, by Charles Hayward, 1974, $8.95 from WEA. Available in the AT Library.
"The craft of woodwork consists largely of joining pieces of wood together. In this book we have taken the basic joints, given their chief variations, and shown how to cut them. It is not suggested that the methods of cutting described are the only ones possible ... but it can be taken that the way described is useful and has been proven by experience to be reliable."
This book is suitable for anyone experienced in working with wood who wants to learn different methods of making joints.
The Making of Tools, Available in the AT Library. INDEX CODE MF 04-103, book, 93 pages, by Alexander Weygers, 1973, Van Nostrand, out of print, but still available for $11.95 from WEA. Available in the AT Library.
"This book teaches the artist and craftsman how to make his own handtools: how to design, sharpen, and temper them, using only basic shop equipment and scrap steel." There are many illustrative drawings on each page that show the "step-by- step progression from the raw material to the finished product—the handmade tool."
Raw material is usually high-carbon steel—from steel scrapyards and auto junkyards (U.S.). Hardwood is used for the handles.
Contents include: tempering steel, sharpening tools; making a screwdriver,.cold chisel and other simple tools; stonecarving tools; cutting tools; eyebolts and hooks, tool handles, hammers, gouges, seating cutter and hinge joints, tinsnips, wire and nail cutters, large shears, and pliers; applying color patina to steel surfaces. There is also a glossary of tool-making terms (useful to non-native English speakers).
The author was born in Java, educated in Holland as an engineer, and has worked in Java and the U.S. before concentrating on art. This book, based on his teaching experiences is designed for the artist and craftsperson who is interested in making (or forced to make) his or her own tools.
The Modern Blacksmith, Available in the AT Library. INDEX CODE MF 04-108, book, 96 pages, by Alexander Weygers, 1974, Van Nostrand, out of print, but available for Dfl. 29.90 from TOOL. Available in the AT Library.
This book is very similar to Weygers' previous book The Making of Tools, but the focus is on things that can be made with hammer, anvil and forge. The basic skills of blacksmithing are covered in detail.
There is an initial chapter on elementary blacksmithing exercises: squaring and straightening a round bar and shaping the end of a square rod. Further chapters include: tempering and hardening high-carbon steel, making a small anvil from a railroad rail (see drawing), and upsetting steel (making a bolt head). There is a glossary of blacksmithing terms.
This is a very good introduction to the skills of blacksmithing, with many drawings and examples.
The Recycling, Use and Repair of Tools, Available in the AT Library. INDEX CODE MF 04-116, book, 112 pages, by Alexander Weygers, 1979, Van Nostrand Reinhold, out of print. Available in the AT Library.
"The scrap steel yards across the country are full of every conceivable metal object discarded for reasons of wear, obsolescence, or damage. Much of this material can become useful stock for the beginner, as well as the skilled metal craftsman, who intends to 'make do' with what can be gleaned from this so-called junk."
In this book the author uses more than 600 drawings to show how to make useful woodworking and metalworking tools and other implements from steel scrap and discarded machine parts. Punches, chisels and gouges can be shaped and forged from steel tubing, automotive shafts, and spring steel. Files, rasps, fireplace tools, candlesticks, and other decorative implements can be made from mild and high-carbon steel scrap. Detailed perspective drawings show how to make a wood-turning lathe from salvaged materials, and adjustable bearings from fruitwood. The final third of the book discusses rehabilitating and operating metal-turning lathes, and how to use and make inserts for a trip-hammer. A short section on how to temper high-carbon steel is included, but in general it is assumed that the reader has basic blacksmithing skills. The author's previous book The Modern Blacksmith (see review) provides a good introduction to the use of the hammer, anvil, and forge.
"It is through actual demonstration, seeing how to manipulate tools to make tools, that I believe the student benefits most. But short of that one can learn from books in which the illustrations come as near as possible to live demonstrations. I have tried to present the information in such a way that the reader can imagine he is watching me making things in the shop."
A practical book illustrating a creative craftsman's approach to repair and reuse.
The Blacksmith's Craft: An Introduction to Smithing for Apprentices and Craftsmen, book, 116 pages, by CoSIRA/Rural Development Commission, 1955, £11.50 surface mail from Rural Development Commission, 141 Castle Street, Salisbury, Wiltshire SP1 3TP, England. Available in the AT Library.
15% of each order supports Village Earth.
This well-written book is divided into 37 lessons to teach people the basic skills of blacksmithing. These sections cover the tools and techniques very thoroughly, and the many photos show each step in making chain links, u-bolts, harrow bars, and many other things. There is a list of books recommended for further reading.
This is possibly the best introduction to blacksmithing available.
Originally published in 1889, Practical Blacksmithing is a compilation of a great variety of articles on different aspects of the craft. These articles, originally printed in the 19th century journal The Blacksmith and Wheelwright, were submitted by hundreds of blacksmiths from all over the United States. This book thus represents an extraordinary attempt to collect, preserve, and make available common "hands-on" wisdom about a critically important craft. Hundreds of drawings show tools, layout of blacksmiths' shops, and methods of working steel and iron which had previously been passed from individual smiths to a few apprentices.
This is an outstanding reference book, to go with the teaching books The Modern Blacksmith and The Blacksmith's Craft (see reviews).
Blacksmithing, Available in the AT Library. INDEX CODE MF 04-85, book, 109 pages, by James Drew, 1943, out of print in 1985. Available in the AT Library
This book covers most simple blacksmithing skills for forging metal parts— especially useful in making and repairing agricultural implements. The chapters include: forging iron and steel, simple exercises in blacksmithing, forging and tempering steel tools, plow work, soldering and brazing. The chapter on forging steel tools covers chisels, drills, and knives. The explanations are clear, although there are only a few drawings.
This book would be a useful introductory book in an area where blacksmith facilities are desired. Experienced blacksmiths, however, will probably find the information too elementary.
Hardening and Tempering Engineers' Tools, Available in the AT Library. INDEX CODE MF 04-98, 89 pages, by G. Gentry 1950, revised by E. Westbury and reprinted 1985, Argus Books Ltd., United Kingdom, out of print. Available in the AT Library
"The efficiency of cutting tools employed in engineering and other crafts depends very largely on their correct heat treatment. In the past, the methods employed in these processes have often evolved individual methods which have been in some cases closely guarded as trade secrets. There is, however, no reason why even the novice should not be able to harden and temper tools quite successfully by adopting simple methods which can be applied without the need for elaborate equipment."
This book contains all the relevant information on simplified processes available to craftspeople with small workshops to maintain their tools in proper working strength for a long lifetime. Detailed descriptions of case hardening and the latest processes, materials and equipment are included, plus valuable information on gas hardening, nitriding, and flame hardening. Although emphasizing modern appliances and conveniences such as welding torches and gas and electric furnaces, a very helpful chapter on forging reminds toolmakers of the importance of shaping steel by hot working under the hammer. This is precisely the state of the art for most traditional blacksmiths in developing countries, for whom the tempering suggestions should prove valuable.
Good illustrations with clear text.
Oil Drum Forges, Available in the AT Library. INDEX CODE MF 04-110, dimensional drawings, 40 pages, ITDG, out of print. Available in the AT Library
Making these forges requires no welding or brazing. One forge is bellows-operated; the other is fan-operated. Both are made from old oil drums. The plans are very simple—numbered drawings (with separate text, to simplify translation) with English and metric measurements.
These can be used by one person for any kind of blacksmith work. The author notes that these devices are also "suitable as engineering exercises, as rural craftsmen must be able to make their own tools."
A Blacksmith's Bellows, Available in the AT Library. INDEX CODE MF 04-84, plans, 23 pages, by Allen R. Inversin and D. Sanguine, 1977, South Pacific Appropriate Technology Foundation, Boroko, Papua New Guinea, out of print. Available in the AT Library
The South Pacific Appropriate Technology Foundation (SPATF) has been organized by the government of Papua New Guinea to develop and promote the use of technologies encouraging individual and village self-help and self-reliance. This booklet, one of SPATF's "how-to-do-it" publications, shows how to construct a hand-operated double-action bellows. Rubber from old inner tubes is used for the flap-valves as well as for the bellows themselves. The simple step-by-step instructions are accompanied by large, clear drawings and an explanation of how the finished mechanism works.
The design in this booklet could be built or adapted at very low cost for any kind of blacksmithing.
Metals for Engineering Craftsmen, book, 69 pages, CoSIRA/RDC, 1964, £8.00 by international money order from Rural Development Commission, 141 Castle Street, Salisbury, Wiltshire SP1 3TP, England; also available from ITDG. Available in the AT Library
This book is designed to be a simple guide to the properties of a wide range of metals and to be a useful alternative to very large technical books on metallurgy. The characteristics of most useful metals are all included along with information such as the welding and casting properties of each. This is not a how-to book, but it is very informative.
Metallurgy, Available in the AT Library. INDEX CODE MF 04-106, book, 472 pages, by C.G. Johnson and W.R. Weeks, 1977, $20.76 ($15.72 for schools ordering two or more) from American Technical Publishers Inc., 1155 West 175th Street, Homewood, Illinois 60430, USA; limited supply. Available in the AT Library
Intended for those who require cast metals of high strength and durability, this book is biased towards the high-technology metals industries. There is, however, plenty of background information that could be useful to small-scale operations. A general introduction to the science of metals, the book covers the properties and testing of materials and the treatment and production of a variety of ferrous and nonferrous metals and alloys. There is a glossary of terms used in the metals sciences.
This book could be useful as a reference in a large blacksmithing, casting, or smelting operation. Some basic knowledge of chemistry is required.
Lost-Wax Casting: A Practitioner's Manual, Available in the AT Library. INDEX CODE MF 04-130, book, 73 pages, by Wilburt Feinberg, 1983, £6.95 from ITDG. Available in the AT Library
15% of each order supports Village Earth.
"The successful endurance of any technology over thousands of years is an impressive feat; for such a technology to find applications in our modern industrial world is a phenomenon." Metal casting of objects is practiced throughout the world, often using techniques that are centuries old. Despite the rudimentary and unlikely nature of the technology often employed, village craftspeople regularly achieve good results. This book aims to inspire simple, basic improvements and encourage further resourcefulness among practitioners in Africa, Asia, and Latin America, and anyone working with limited resources. Following a discussion of basic techniques, the author presents a number of practical, low-cost suggestions to enhance quality and productivity. The emphasis is on attainable improvements based on the realities of village foundries.
These improvements include mold and pattern-making for low-cost duplication, use of scrap material, formulas for compounds used in modeling, mold-making, kiln construction, and even the production of crucibles in which the metal is melted. Metal casting (for machine parts, tools, hardware, and so on) is a technology with great potential for local employment generation and enhanced self-reliance.Though somewhat brief, this book could contribute greatly to the quality of production and economic viability of village-level foundries. Includes case studies and technical appendices.
 |
Foundrywork for the Amateur, Available in the AT Library. INDEX CODE MF 04-94, book, 108 pages, by B. Aspin, 1954 (revised 1986), Model and Allied Publications, £5.95 plus £0.75 shipping from Argus Books, Argus House, Boundary Road, Hemel Hempstead, Hertfordshire HP2 7ST, England. Available in the AT Library.
15% of each order supports Village Earth. |
A basic skills book for making metal castings, describing the tools and techniques needed. The requirements are simple, although some of the tools described may not be locally available (such as a ceramic crucible). A foundry can be very useful for producing metal tools and replacement parts. Scrap metal can often be used, and the tools can often be made.
The book covers subjects such as furnaces, sand, molding boxes, how to make and ram a mold, and melting iron and aluminum. Illustrations of the tools used and the steps in the casting process are included. Useful examples are given, such as the casting design for an engine crankcase. Some of the English is a little complex. Although this book was written for use in Britain, it should be valuable in rural areas where foundry skills are needed to produce things locally.
Small-Scale Foundries for Developing Countries: A Guide to Process Selection, Available in the AT Library. INDEX CODE MF 04-127, book, 66 pages, by J.D. Harper, 1981, £6.50 from ITDG; also available from TOOL. Available in the AT Library
15% of each order supports Village Earth.
"This book is not intended as a textbook of foundry practice. The purpose is rather to assist anyone about to start or to expand a small-scale foundry to consider the various available processes, and to select the most appropriate for the circumstances. An indication is given of the type of raw materials and equipment which will be needed, and the degree of training or skill which is likely to be required."
Smelting Furnace, Popular Mechanics Plan X297, Available in the AT Library. INDEX CODE MF 04-113, 5 pages, by E.R. Haan, 1964, $3.75 from Popular Mechanics. Available in the AT Library
15% of each order supports Village Earth.
"With this small furnace you can smelt aluminum, brass and copper; preheat small, thick pieces of iron and steel for brazing or forging; caseharden soft steel; make up alloys .... You can use either LP or city gas. The cost is about $25 (1964 prices)." The furnace is about 17 inches high and 12 inches in diameter; it holds a 3- inch diameter crucible. Clear photos and drawings with the text show how to make and operate the smelting furnace. A vacuum cleaner is needed to supply forced air. This might be of use in a small workshop where casting work is occasionally done.
Fabricating Simple Structures in Agricultural Engineering, book, 68 pages, 1955, Council for Small Industries in Rural Areas/Rural Development Commission, out of print. Available in the AT Library
"This volume has been prepared by the Rural Industries Bureau as a guide to blacksmiths and agricultural engineers. It deals with the application of oxygen cutting and arc welding fabrications and therefore assumes knowledge of these two processes."
The structures described are all metal and are generally used in farm applications: linkage mechanisms, wheels, rollers and brackets, bearing mountings, trusses, gates and a trailer chassis design. All pieces are made out of angle, channel and plate iron.
"The fabricated parts used to illustrate this book are intended to teach principles; they are not primarily intended to represent actual parts of machines. The object is not to show the precise way in which an exact number of fabrications can best be made, but rather to help the reader to become 'fabrication minded.' " The emphasis is on helping the reader fabricate parts of his own design.
The Procedure Handbook of Arc Welding, Available in the AT Library. INDEX CODE MF 04-115, book, 630 pages, 1973, $6.00 plus $2.00 surface mail postage (10% discount on orders over $10) from The Lincoln Electric Company, P.O. Box 17035, Cleveland, Ohio 44117, USA. Available in the AT Library
15% of each order supports Village Earth.
This remarkably thorough and detailed book tells you probably everything you would ever want to know about small and large-scale electric arc welding. It "is directed toward those people who have day-by-day working interest in arc.welding— to the supervisory and management personnel of fabrication shops and steel erection firms; to welders and welding operators; to engineers and designers; and to owners of welding shops. The editorial aim has been to be practical—to present information that is usable to those on the job." The authors have also attempted to make the text as understandable as possible to the beginner.
Following an introduction to the fundamental principles of electric arc welding, the topics covered include preheating, relieving stress, welding different types of metals, safety, and welding underwater, in addition to power sources, equipment and supplies for arc welding.
There is an extensive reference section containing data on weights, hardness of different materials, and etching methods. There are many illustrations and a good index. Readers should have some understanding of basic welding methods.
Welding Craft Practices, Volumes 1 and 2, Available in the AT Library. INDEX CODE MF 04-126, books, 159 pages (Volume 1) and 182 pages (Volume 2), by N. Parkin and C. Flood, 1969, paper editions out of print, microform editions available from O.P. Books Department, Pergamon Press, Maxwell House, Fairview Park, Elmsford, New York 10523, USA. Available in the AT Library
"The two volumes of this book cover the ground necessary for the acquisition of the essential basic skills and safe working methods in welding, sufficient technology and related studies being included to provide a suitable background to the practical work and form a basis for further, more advanced studies. It is intended for all who wish to learn to weld, and the ground covered will enable the beginner to obtain a sound knowledge of the equipment, an appreciation of safety and, by means of a graduated series of practical exercises, a good standard of skill.
"Volume 1 deals with Oxygen-Acetylene Processes and Weld Defects, Testing of Welds, and Welding Science; Volume 2 with Electric Arc Processes and Elementary Electricity, Classification of Electrodes, Welding Symbols, Engineering Drawing, Metal Plate Surface Development and Workshop Calculations." These latter sections on drawing and welding symbols could be useful references for those who work with dimensional/mechanical drawings.
The two volumes can be bought separately; both have drawings and a few photographs. While welding is a skill that must be learned by practice, usually with the help of an experienced welder, these two books are well-suited to library or textbook use.
3 Welding Jigs, ITDG Complete Technical Drawings No. 19 ,3 large sheets, by R. Mann, ITDG, out of print. Available in the AT Library
Welding jigs are used to hold parts in place and facilitate the repetition of a welding task during the fabrication of identical steel items. These drawings provide details on three jigs: a "plow share" jig for repair or fabrication of irregular sections, a shift and stock jig, and a universal jig. Exploded views are included along with materials lists. Although measurements are given, it is noted that the dimensions are approximate and can be varied to suit the local availability of materials and particular jig requirements.
Farm Shop and Equipment, Available in the AT Library. INDEX CODE MF 04-93, booklet, 16 pages, 1953 (reprinted 1975), Cumberland General Store, out of print. Available in the AT Library
"Farm machinery is important to self-sufficiency. Effective care and repair of farm machinery requires an organized farm shop, as well-equipped as possible."
This booklet was originally written for small American farmers. It discusses the kind of work that can be done, desirable building features, and a simple equipment list for making repairs in a farm shop. It shows how to sharpen and grind drill bits and how to make a chisel. One of the unique features of this booklet is a full-page table in which the following are listed: major kinds of metals used in farm machinery, how to identify them, why the manufacturer used the particular metal, common causes of failures, and recommended method of repair. There are numerous diagrams and photos, including a farm-made substitute for a drill press that uses a hand electric drill and simple plumbing parts, and dimensional drawings for a medium-sized brick forge.
Sheet Metal Former, Plan No. X609, Available in the AT Library. INDEX CODE MF 04-112, 7 pages, 1966, $5.25 from Popular Mechanics. Available in the AT Library
This hand-operated tool allows you to make perfect cylinders in any diameter from 1 5/8’’ up. It will handle 20-gauge sheet iron up to 12’’ wide and thicker pieces of softer metals.
Two important pieces are cut from aluminum alloy plate; production will be more difficult if steel is used. This tool will require a lot of precision metal work to make.
How to Work Sheet Metal, Available in the AT Library. INDEX CODE MF 04-100, book, 142 pages, by Herbert J. Dyer 1963, Model and Allied Publications, U.K., out of print in 1986. Available in the AT Library.
15% of each order supports Village Earth.
This book outlines methods of sheet metal working using techniques and equipment that stress low-cost efficiency. Riveting, soldering, brazing, and other metal joining techniques are discussed as well as sheet edging and shaping methods. Includes sections on equipment, materials, and metalworking machines. Also included are dimensional drawings of a few basic sheet metal tools and equipment.
A beginner may at times have difficulty following the text; but, on the whole, an excellent book.
How to Make a Folding Machine for Sheet Metal Work, Available in the AT Library. INDEX CODE MF 04-99, booklet, 32 pages, by Rob Hitchings, 1985, £3.95 from ITDG; also available from TOOL. Available in the AT Library or individual book here 15% of each order supports Village Earth.
Clear text and drawings distinguish this guide to building a simple yet effective and versatile tool for sheet metal work. The required materials and equipment should be available in most rural or semi-rural locations and the resulting machine will produce superior quality work with a great savings in time when compared with hand materials.
Sheet Metal Brake, Plan No. X606, Available in the AT Library. INDEX CODE MF 04-112, 8 pages, by Manly Banister, 1964, $6.00 from Popular Mechanics. Available in the AT Library
This is a valuable, versatile, simple workshop tool for quickly and accurately bending sheet metal. For use in workshops where a lot of sheet metal bending is done or where precision is important. Hand-operated. The tool is 18 inches wide and can bend up to 20-gauge sheet metal the full width, or thicker narrower pieces.
"By using the proper forming block or mold, you can bend sheet metal to any angle, make radius bends, reverse bends, and seams." Part II describes techniques for.the effective use of the tool.
Metal Bending Machine, Available in the AT Library. INDEX CODE MF 04-105, dimensional drawings and photos, 24 pages, ITDG, out of print in 1985. Available in the AT Library or individual book here 15% of each order supports Village Earth.
This remarkably simple machine can be used to bend thin strips of metal (the width can be varied), from right angle bends to circular rims for cart wheels. It is hand-operated by two people, and has very few parts.
The booklet has very detailed drawings with English and metric measurements. It also includes instructions and photos on how to make cart wheels with an axle jig assembly. Several ITDG designs use wheels fabricated with this machine (see the agricultural leaflet entitled Carts). An ingenious piece of intermediate technology.
Try Your Hand at Metal Spinning, Popular Mechanics Plan X420A, Available in the AT Library. INDEX CODE MF 04111, 5 pages, by Sam Brown, 1954, $3.75 from Popular Mechanics. Available in the AT Library
This is a set of directions for making bowls out of aluminum by bending it into the proper shape on a lathe. No cutting is involved. "If you begin with soft aluminum and work it over a simple form you can spin a bowl in less than five minutes after the job is set up. Aluminum spins very easily and does not tend to score or buckle under the forming tools " Drawings and photos illustrate the techniques and special tools needed (simple to make). Requires 16- to 22-gauge aluminum. The lathe has to operate at about 900 rpm.
General Metal Work, Sheet Metal Work and Hand Pump Maintenance, Rural Mechanics Course 1, Available in the AT Library. INDEX CODE MF 04-134, book, 189 pages, by John van Winden, 1990, Dfl. 19.00 from TOOL. Available in the AT Library
This is the first in a series of books intended for use in a four-year course for rural mechanics, who are expected to have only a very limited toolkit without power tools.
Most of this book is on the elementary use of basic hand tools. Since a rural mechanic is a likely candidate for handpump repair, a short section is devoted to maintenance of several common handpump designs. Another short section introduces pipes and pipefitting. The last section contains 35 pages on various sheet metal forming techniques.
Blacksmithing, Welding and Soldering, Rural Mechanics Course 2, Available in the AT Library. INDEX CODE MF 04-133, book, 142 pages, by John van Winden, 1989, Dfl. 17.50 from TOOL. Available in the AT Library
Part of a four-book series for a four-year rural mechanics training course, this volume covers the basic heavy metalworking tasks that a rural blacksmith/mechanic with limited tools might expect to encounter. A broad range of blacksmithing techniques are presented, and these are exceptionally well-illustrated.
Also included are exercises that require the use of most of these techniques in the production of commonly needed tools. A more limited set of techniques for electric arc welding and gas welding are covered. Unusual items here include instructions on how to weld joints without a welding rod, and drawings with a description of the proper use of an acetylene gas generator to make acetylene on the spot..The coverage of soldering is limited to sweating a lap joint. There is no coverage of soldering copper pipe.
Metalworking Handbook: Principles and Procedures, Available in the AT Library. INDEX CODE MF 04107, book, 480 pages, by Jeannette T. Adams, 1976, ARCO Publishing Company, New York, out of print. Available in the AT Library or individual book here 15% of each order supports Village Earth.
This book is both a manual for the beginner and a reference book for the skilled craftsperson. For example, you'll find an introduction to working with sheet metal, soldering, riveting and metal spinning. A variety of machine tools are discussed: drilling machines, milling machines, shapers, planers, lathes, and grinding machines. The appendix offers many useful tables.
Workshop Exercises Metal, Part A, Fundamental Skills, Available in the AT Library. INDEX CODE MF 04-129, book, 90 pages, and Technology Metal 1, Part A, Fundamental Skills, Available in the AT Library. INDEX CODE MF 04-128, book, 90 pages; 1982, edited by H.N.C. Stam, Dfl. 25.00 each from TOOL. Available in the AT Library
Technical and vocational education in developing countries can benefit from clear and easy-to-understand texts on workshop skills. The pictorial system and straightforward language of this pair of workbooks make them appropriate for beginning shop classes anywhere metalworking tools are available. The exercises require the production of practical objects that develop skills in layout, measurement, metal-cutting, forming and fastening. The tools required may be somewhat sophisticated for typical rural workshops and schools. But where the resources are available, and a curriculum for enhanced industrial capability is desired, these books will be useful.
The Beginner's Workshop, Available in the AT Library. INDEX CODE MF 04-83, book, 244 pages, by Ian Bradley, 1975, Model and Allied Publications, U.K., out of print in 1986. Available in the AT Library
This book will introduce you to the basic tools and machines in a metalworking workshop. The author provides suggestions on buying tools and building some small items. The basic uses of the tools and machines are very well-described.
Recommended for the reader wishing to develop basic workshop skills. Readers who already have such skills may find some new information here too.
Amateur's Workshop, Available in the AT Library. INDEX CODE MF 04-80, book, 256 pages, by Ian Bradley, Model and Allied Publications, 1976, revised edition 1986, £8.50 plus £0.85 shipping from Argus Books Ltd., Argus House, Boundary Way, Hemel Hempstead, Hertfordshire HP2 7ST, England. Available in the AT Library or individual book here 15% of each order supports Village Earth.
This book is intended for people who already possess at least the basic skills of metalworking using hand and power tools. Despite the use of the term "amateur" in the title, this book contains an enormous amount of useful information The text is clear and well-illustrated. Workshop skills are thoroughly covered. There are many detailed plans for tools and attachments to tools; many of these are complex devices.
Amateur's Workshop will help someone with basic skills become a skilled craftsperson, after lots of practice. The book would be especially useful in programs for training metal workers. There is no glossary.
This is a step beyond The Beginner's Workshop, by the same author. An excellent book.
Heavy Duty Drill Press, Plan No. X245, Available in the AT Library. INDEX CODE MF 04-111, 4 pages, by Arthur B. Farwell, $3.00 from Popular Mechanics. Available in the AT Library
This appears to be a very sturdy, powerful drill press for heavy drilling in wood and metals. An imaginative design, yet reasonably simple to make. A small amount of machine shop work would be needed on a few minor parts. A small electric motor is used, but a geared-up pedal-power unit would work also. The drawings are quite clear and sufficiently detailed. This is a possible substitute for expensive heavy duty imported drill presses for many circumstances.
How to Mill on a Drill Press, Plan No. X422A, Available in the AT Library. INDEX CODE MF 04-11 l, 5 pages, by Kenneth B. Littlefield, 1969, $3.75 from Popular Mechanics. Available in the AT Library
This article includes plans for cutting attachments that can be added to a metalworking drill press to enable you to do milling work. It also describes the techniques to use.
Available in the AT Library. INDEX CODE MF 04-95, book, 92 pages, by A.W. Marshall, 1984, out of print; replaced by Gears and Gear Cutting">Gear Wheels and Gear Cutting, Available in the AT Library. INDEX CODE MF 04-95, book, 92 pages, by A.W. Marshall, 1984, out of print; Available in the AT Library or individual book here 15% of each order supports Village Earth.
Available in the AT Library. INDEX CODE MF 04-95, book, 92 pages, by A.W. Marshall, 1984, out of print; replaced by Gears and Gear Cutting">replaced by Gears and Gear Cutting, by Ivan Law, 1987, £6.95 plus £0.70 shipping from Argus Books Ltd., Argus House, Boundary Way, Hemel Hempstead, Herts HP2 7ST, England. Available in the AT Library
"An elementary handbook on the principles and methods of production of toothed gearing." The author tells why and how to design and make gears. He discusses gear principles and tooth shapes, a wide variety of gears (including bevel and chain gears), and cutting gears on standard metalworking machine-tools. A knowledge of basic geometry is necessary in order to use this book.
Making gears is a complex task that requires a workshop with at least a metalworking lathe and drill press. This is a good guide to the process.
10-inch Table Saw, Plan No. X585, Available in the AT Library. INDEX CODE MF 04-111,10 pages, by Elman Wood, $7.50 from Popular Mechanics. Available in the AT Library
This unit would involve quite a bit of machine shop metal work, but the plans are quite clear, and the final product would be a solid, versatile table saw. The 10-inch circular blade can be raised, lowered, or tilted. The electric motor would be difficult to replace with another power source.
4-Wheel Band Saw, Plan No. X36, Available in the AT Library. INDEX CODE MF 04-111, 4 pages, by H. Tuttle and R.E. Knull, $3.00 from Popular Mechanics. Available in the AT Library
"Except for ball bearings and retainers, metal yokes, sheet-metal cover, and such shafts and bolts as are necessary in the assembly, the machine is entirely made out of wood. Most of the parts are cut from a single piece of 5/8" plywood." The four wheels are made of plywood, and covered with pieces of inner tube to provide a surface against which the blade rubs as it rotates. A pulley can be changed to allow a second speed. Uses blades 10 feet long and up to l/2-inch wide. The small electric motor could be replaced by a 1-2 person pedal-power unit with a flywheel. Will cut.wood and light metals (this requires changing to a metal-cutting blade and operating at a lower speed). Clear drawings, sufficient for construction.
Two-Speed Bandsaw Cuts Wood and Metal, Popular Mechanics Plan No. X37, Available in the AT Library. INDEX CODE MF 04-112, 7 pages, by A.L. Mills, 1951, $5.25 from Popular Mechanics. Available in the AT Library
This machine can be used to cut wood or metal, by shifting v belts between pulleys to change the speed of the blade. "It has every essential feature of the average dual purpose type machine." The frame is made of water pipe and fittings, while the band wheels are made of hardwood.
DeCristoforo's Book of Power Tools, Both Stationary and Portable, Available in the AT Library. INDEX CODE MF 04-88, book, 434 pages, by R. DeCristoforo, 1972, Times Mirror Magazines, New York, out of print. Available in the AT Library
A clearly written, extensively illustrated guide to the use of power woodworking tools, both stationary and hand-held. Includes table saws, drill presses, lathes, band saws, belt sanders and more. Each chapter describes the safe operation of a tool, and standard techniques, as well as many innovative applications of that particular machine. Most useful are photos and plans for simple jigs and accessories which increase the versatility of the power tools and allow the production of many identical pieces. For example, there are plans for an adjustable wooden frame for cutting large panels easily with a power hand saw.
This book only provides instruction in the proper use of commercially available machines. No design and construction details for such machines are provided. The greatest weakness of this book is that it includes almost no information about repair or even routine maintenance of the power tools. May be useful to those wishing to teach themselves wood shop techniques, especially for small-industry furniture production.
Motorize Your Hacksaw, Plan No. X334, Available in the AT Library. INDEX CODE MF 04-112, 2 pages, by Carl S. Bates 1952, $1.50 from Popular Mechanics. Available in the AT Library
"If you have a small metal working shop or use steel bar or shafting to some extent in your home workshop, motorizing a hand hacksaw will save hours of work and can be done at a fraction of the cost of a commercial power hacksaw. The inexpensive drive unit consists of an 8- or 10-inch v-pulley and shaft, a connecting rod and a guide rod, a vise or clamping arrangement to hold the work and a suitable wooden base. When needed for handwork, the saw can be removed from the unit in a few minutes." Uses a l/4 hp electric motor.
Scroll Saw, Plan No. X594, Available in the AT Library. INDEX CODE MF 04-112, 5 pages, by Will Hooper, 1945, $3.75 from Popular Mechanics. Available in the AT Library
This saw is similar to a jig saw, with a narrow, reciprocating blade. The plans have to be studied carefully to be fully understood. This design is made of hardwood and a variety of small metal parts from old automobiles. Some cutting, drilling and tapping steel is required. Uses a 1/4 hp electric motor. Appears to be a sturdy machine.
Metal Turning Lathe Built from Stock Parts, Plan No X387, Available in the AT Library. INDEX CODE MF 04-113, 4 pages, by Frank Beatty, 1959, $3.00 from Popular Mechanics. Available in the AT Library
This metalworking lathe is not a precision tool. It can accept work up to 4 1/2’’ in diameter and 10’’ long. Standard pipe and fittings are used to form a frame on which the rest of the lathe is fitted. Precision metal work is required to make this lathe.
Lathe Sanders, Plan No. X388, Available in the AT Library. INDEX CODE MF 04-112, 2 pages, by Dick Hutchinson, 1949, $1.50 from Popular Mechanics. Available in the AT Library
This article provides ideas for making simple disc and drum sanding attachments for use with a woodshop lathe. Also shows another drum sander powered by an electric drill.
Wood Planer for $100, Popular Mechanics Plan No. 802B, Available in the AT Library. INDEX CODE MF 04-112, 9 pages, by Ronald Guy, 1970, $6.75 from Popular Mechanics. Available in the AT Library
This is a workshop machine for planing wood to a specified thickness.
Metalworking tools are needed to do a lot of precision work to make this machine.
Cost $100 for materials in 1970. Useful in converting scrap, low-grade, or recycled lumber into more valuable boards.
A Manual on Sharpening Hand Woodworking Tools, Available in the AT Library. INDEX CODE MF 04-104, large booklet, 48 pages, by J.K. Coggin, L.O. Armstrong, and G.W. Giles, 1943, $4.00 from Interstate Publishers, 19-27 North Jackson Street, Danville, Illinois 61832, USA. Available in the AT Library or individual book here 15% of each order supports Village Earth.
Written and published as a shop manual for students in woodworking and industrial arts classes in rural schools. Drawings and simple instructions show how to grind and sharpen chisels, plane irons, saws, augers, knives, axes, and screwdrivers. Many of the illustrations are clear and complete enough to be used without the text. Includes simple explanations of types of steel used in hand tools, and an illustrated glossary of sharpening terms.
An excellent low-cost teaching tool and reference.
Sharpening Small Tools, Available in the AT Library. INDEX CODE MF 04-117, book, 128 pages, by Ian Bradley, 1980, MAP Publications (U.K.), $7.95 from Sterling, 2 Park Avenue, New York, New York 10016, USA. Available in the AT Library or individual book here 15% of each order supports Village Earth.
"In this book the sharpening of tools in general use is dealt with, and, whenever possible, simple and well-tried methods have been adopted, bearing in mind that usually the aim when sharpening a tool should be to restore, as accurately and as consistently as possible, the original form of the cutting edge." Bradley begins with an introduction to the materials and equipment used in sharpening. Then he explains (with illustrations) the proper sharpening techniques to use with metalworking tools lathe cutting tools, shears, drill hits, and other tools used in boring. This is followed by sharpening techniques for woodworking tools— planes, saws, chisels, and drill bits—and some common household tools such as knives and scissors.
When a sharpening "stone is used dry, it will soon become filled with metal particles and ... have little abrasive action .... Water or oil is applied to the stone to.enable the metal dust to be carried away ...."
"The four common forms of cold chisels ... are generally sharpened on the grinding wheel, [although] when the edge is but little blunted it can readily be restored on a coarse emery bench stone."
Bearing Design & Fitting, Available in the AT Library. INDEX CODE MF 04-82, paperback book, 80 pages, by Ian Bradley, 1979, Model and Allied Publications, U.K., out of print in 1986. Available in the AT Library
"Although the subject of this book is complex and covers a very wide field, an attempt has, nevertheless, been made to deal with the main principles involved and, at the same time, to furnish examples of bearing design and application that may be found of use particularly in the small workshop."
Bearings are used whenever something rotates or slides against something else and it is desirable to reduce friction and wear. This book is good on the design and production of metal bearings. Many of the ideas could be applied to other materials, such as wood, of which bearings are often made in developing countries. The book covers casting of bearings from metals and plastics, machining bearings, design, lubrication, different types, and maintenance and repair. See also Oil Soaked Wood Bearings, reviewed on page 221.
Spring Design and Calculation, Available in the AT Library. INDEX CODE MF 04-119, book, 37 pages, by R.H. Warring, 1973, Argus Books, out of print. Available in the AT Library
This book tells you how to make metal springs. Topics covered include spring materials and the following kinds of springs: flat, helical, tapered helical, torsion, clock, constant force, and multiple leaf. Wire sizes and other details of spring construction are also discussed. Simple algebra is needed to design springs using this book.
"Spring design proportions are not something that can be 'guesstimated' with any degree of accuracy—and trial-and-error design can produce a succession of failures. Thus this book on spring design is full of formulas, as the only accurate method of predicting spring performance. However, all are practical working formulas; and all are quite straightforward to use." |
