We are making a coat hook with lots of areas on it where you can hang items of clothing.This is a very good thing to make because a lot of the time I don't have enough space to hang up all of my clothes. It is going to be very easy to hang all your clothes on and it looks very nice and pretty.
It is not a very difficult thing to make apart from you have to go through quite a lot of steps, but the material that you are using is quite easy to handle.
I want to make my design bright and good looking. It has to be safe so it must have round edges so it isn't sharp, and the wood and metal must be sanded down so it is not rough.
Step 1: Making the Paper Model
We have to make a paper model of one of the shapes which is going to go on our coat hook. We have to draw the shape that we want on a piece of paper and draw dotted lines on the parts of the shape which are going to be folded over to make it 3D. We have to draw the shape with right measurements so that when we do the shape on the metal it fits. It needs to be perfect so that when the parts of the shape fold over it fits in perfectly with the rest of the shape.
We need to use: a pencil
a ruler for straight lines
paper for the model
You are creating the net of your shape on paper before you cut your shape out on metal.
Step 2: Metal
Once we have done the shape on the paper, we have to put it on the metal. The metal is quite rough around the edges so we have to file it down so it is not sharp and dangerous, we do this by using a file. After we have filed all the edges we have to go over the piece of metal with a piece of sand paper to get all of the marks which are on the metal to go away and it also makes it very smooth. Once we have finished making our metal ready for us to use we then get our paper template of the shape that we have chosen and we unfold it so it is flat and we lie it down onto the metal. Once it is down on the metal we draw around the shape onto the metal so that we then have the shape on the metal, but because the lines are quite faint because we have just drawn around them with pencil we then go over the lines with a pointy thing but to make sure they are straight when we go over them we use a steel rule to make the lines straight.
Once we have everything onto our metal we have to cut out our shape. We put the piece of metal in the vice so it is easy to cut and we get a junior hack saw to cut the metal. When we are cutting the metal we want to put it as low down in the vice as you can so that when you are cutting it is not moving around and it could snap. Once we have cut out our shape it will be ruff around the edges so we will have to file the edges down and make them smooth and we do this by using the same tool as before.
Step 3: Making a Hole in the Metal
Once the shape is cut out we have to put a hole in the piece of metal somewhere so that when it goes on out coat hook it can go on. We put the hole through it but thirst marking it where we want the hole to go with a marker, we then go to the drilling machine and we line up our hole on our metal with the drill to get the hole to go through exactly where we want it to go through. We push the handle of the drill machine down gently into the mark on the mettel and really slowly keep twisting the handle intel we fell it bite and that means it has gone all the way through.
Step 4: Bending the Metal.
We have to bend our metal down our folded lines to make the shape that is going to go on our coat hook. We do this by fist of all putting our shape into a vice and putting the edgge of the metal exactly on the edge of the vice on the folding line. Once it is all lined up we get a malet and hit the bit we want to bend and make it as flat as we can and hit along the edge where it has been bent so there is a clear line. We take our hsape out of the vive because we need to make out piece of metal more bent until it looks like the shape it should be. We get a holder which is attached to the table and we put it on top of the metal so it holds it and it doesnt move around, we then get our and hit the edge of the bent side more until the the bent bit is looking the shape it should be and you do this to the otherside aswell until both sides look the same.
Step 5: Platic Dip-Coating
Once you have finished cutting and bending the metal, we have to dip coat our metal to make it a colour.
For doing this step we have to use an oven to heat up the metal, we use the fluidiser for coating the metal, we use coloured plastic powder to colour our meatal. We need metal tongs for when we take out our metal because it will be really hot, and gloves and goggles for safety.
- We first of all put our piece of metal in the oven at approximately 400 degrees, for 20 minutes.
- Once the metal is heated, we take it out using the metal tongs and wearing gloves.
- We turn the fluidiser on, this blows air through the particles causing them to rise up and bubble
- within the tank.
- We dip the metal into the fluidiser, using the metal tongs, until a layer of polymer has melted and adhered to the surface of the hot metal.
- Take the meatal out and let it dry.
Step 6: Cutting the Wood
We have to choose two pieces of wood which are the same lengh and size. We need these because we have to make a lap joint to go on our coat hooks. we mark out on both pieces of wood where we want to cut which is 70mm from the end of the piece of wood, but on the side of the wood we need to make a line down the middle tohalf it so that only half of the wood comes off. We mark this out by using a steel rule and a Try-square and for marking it down the middle we use a marking gauge. once we have got everything measured out we cut down the line across the wood using a tenor saw and we cut down to where the line is in the middle, so that all of the wood does not break off. Once we have done that we use a band saw to cut down the line which halves the wood. we push the wood against the side and we slowly push it into the band saw and the band saw will cut down the line, and we stop once it gets to where our line stops, and half of that section of the wood will have come off and we do that to both pieces of out wood. If when you put the two pieces of wood together nd they dont line up you just ahve to send the end of one of the pieces of wood which is causing the problem and then it will make them fit.
Step 7: Glueing the Wood
Once we have both our pieces of wood completely cut we put PVA glue on the side of the wood where we have just cut the wood off from and then we join the two pieces of wood together so they fit in with eachother and you hold them together with a clamp but you need to protect your wood from the metal clamp so you need your bits of wood which broke off when you cut your wood to protect your lap joint, you then tighten the clamp to hold the wood in place so that they stick together. You have to leave them for a long time so that they will dry, and so that they will not fall apart.
Step 8: Drilling the Wood
We have to make the point on our wood where we need to drill our holes and we do this by measuring the width of the wood and then dividing it by 2 and making a mark where that is and that is where we drill the holes. we use the piller drill with a 10mm drill bit. We slowly twist round the wheel and the drill goes into wherre we marked it and we keep on slowly twisting the handle until we feel the drill go all the way through and we take it out, and we do that to both of our marks.
We put the wooden dowels through our holes and put them through alot so there is a bit of it sticking out a both and and we put a liitle bit of glue inside so that they will stick. We then use a Japanese saw to cut off the ends of the liittle wooden dowels so that there is none sticking out, we do this by putting our wood in the vice to hold it still and then we cut off the little bits to make it completely smooth on the back. We then sand down the wood so that there is no marks on the wood from when we were cutting the dowels.
Step 9: Drilling the Wood for the Dowels
We need to drill two more holes in the wood for our bigger dowels to go through. The dowels stick out of the wood to work as a hook for your clothes to hang off.
We have to measure up where we are going to drill the holes in.
The tools we will need:
1. Try Square
2. Steel Rule
4. Pillar Drill
5. Wood Glue
We mark up the holes by splatting the wood into three and drawing a line down the middle and putting the marks where the lines cross each other.
Step 10: Drilling the Metal Heart Onto the Wood
We need to attach our metal shapes to our wood. We do this by drilling a tiny little hole into our wood but we do not drill the whole way through. We then place our metal shape on the wood with the hole in the metal on top of our hole in the wood, we then get a screw and drill it through out hole in our metal into our hole in the wood and we drill it in till it is tight so that it doesn't move.
What we will need:
1. Your metal shape
2. A drill
3. A screw