handout activity: ha027 - dysart high school ball-peen is used a great deal. the ball-pein hammer...

Basic hand tools

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Basic hand tools

Choose the right tool for the job. Otherwise you could damage the part you are working on, the tool, or yourself.

Wrenches are used to tighten and loosen nuts and bolts. There are three commonly used wrenches: the box, the open-end and the socket. Each one has special uses depending on the leverage needed and the tightness of the workspace. One other wrench, the adjustable or crescent wrench, should only be used if other wrenches aren’t available because it can slip off tight bolts or nuts.

Place a box wrench on a nut. The handle on a box wrench is longer than the open-end wrench. It is also bent, so you can get a full grip on the shank of the wrench. The head grips the nut at six points. This allows you to loosen very tight fasten-ers. Place an open-end wrench on a nut. Notice that the handle is shorter than a box wrench and that it grips the head at two points. This allows you easy access to fasteners. With its offset head, this a good wrench to use in very tight spaces.

The socket wrench is very popular because of its adaptability and ease of use. Place a socket wrench on a nut. You’ll notice that the socket has six or twelve internal teeth; the one with six is stronger. Socket wrenches always need an attachment to turn them. A range of these attachments is included in socket tool sets, making this the workshop’s most versatile wrench.

Examine a flat blade screwdriver. Make sure that the tip fits the slot of the screw correctly. The wrong screwdriver could slip, or damage the head of the screw. If the screwdriver is the correct size, it will fit neatly into the slot with the blade the same width. This will prevent the screwdriver from jumping out of the slot when pressure is applied.

A Phillips screwdriver has a cross on the end of the shaft that fits the star-shaped slot of the screw. A Phillips head can be pushed and twisted with more confidence because of the snug fit, but again the screwdriver must be the right size otherwise you strip the screw head.

The hammer you use depends on the part you’re striking. The hammer face MUST ALWAYS BE SOFTER than the part you’re hammering. This will prevent damage to the part. Hammers are a vital part of the workshop tool kit, and the ball-peen is used a great deal.

The ball-pein hammer gets its name from the ball on the rounded face. It’s usually used for flattening, or “peening”, a rivet. If you can’t find a hammer that matches the size of the job, pick a larger hammer as a rule of thumb.

For certain hammering jobs you would choose a Plastic Hammer. A steel hammer might mark or damage a part especially if it’s made of a softer metal like aluminum. The softer heads will not damage metal parts, and will absorb some of the force of the blow. Some are very soft with rubber or plastic heads. Others will use brass or copper.

Pliers are used for grasping and cutting. Combination pliers are the mostly commonly used in a workshop. However, sometimes you’ll use channel lock pliers. They’re useful for a wider grip and a tighter squeeze on parts too big for conventional pliers.

Diagonal cutting pliers are used for cutting wire or cotter pins.

Long-nosed pliers are used for hard-to-get-at places.

And Snap ring pliers remove snap rings.

Student/Intern information:

Name Date Class

Handout Activity: HA027

Summary Choose the right tool for the job. Otherwise you could damage the part you are working on, the tool, or yourself.

2009 Jones and Bartlett Publishers LLC

Basic hand tools

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Supervisor/Instructor information:

Name Signature Date

Score / 5

1. If you can’t find a hammer that matches the size of the job, pick a ………………………… hammer as a rule of thumb.

2. Pliers are used for grasping and cutting. Combination pliers are the mostly commonly used in a workshop.

However, sometimes you’ll use ………………………… lock pliers.

3. The hammer face MUST ALWAYS BE ………………………… than the part you’re hammering.

4. The ball-peen hammer gets its name from the ball on the rounded face. It’s usually used for flattening, or

“…………………………”, a rivet.

5. The handle on a box wrench is ………………………… than the open-end wrench.


Hammers

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Hammers

The most common hammer in an automotive work-shop is the ball pein or engineer’s hammer.

Like most hammers its head is hardened steel. A punch or a chisel can be driven with the flat face. Its name comes from the ball pein or rounded face. It’s usually used for flattening, or peining, a rivet. The hammer should always match the size of the job and it’s better to use one that’s too big, rather than too small.

Hitting chisels with a steel hammer is fine, but sometimes you need just to tap a component, to position it. A steel hammer might mark or damage it, especially if it’s made of a softer metal like aluminum. In such cases a soft-face hammer should normally be used for the job. Some are very soft with rubber or plastic heads through to those using brass or copper.

When a large chisel needs a really strong blow, it’s time to use the lump hammer. It’s like a small mallet, with two square faces made of high carbon steel. It’s the heaviest type of hammer that can be used one-handed.

The most common mallet in the workshop has a head made of hard rubber. It’s a special purpose tool, and is often used for moving things into place where it is important not to damage the item being moved.

This is a dead blow hammer. It’s designed not to bounce back when it hits something. A rebounding hammer can be dangerous or destructive. Its head is either made of lead, or it’s hollow with lead shot inside. The lead absorbs the blow.


Name Date Class


Summary The most common hammer in an automotive workshop is the ball pein or engineer’s hammer. The soft-face & deadblow hammers are also used.faces.


Hammers

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Name Signature Date

Score / 4

1. The most common mallet in the workshop has a head made of hard rubber. It’s a special purpose tool, and is

often used for moving things into place where it is important not to ………………………… the item being moved.

2. A rebounding hammer can be dangerous or destructive. Its head is either made of …………………………, or it’s hollow with lead shot inside.

3. Some are very soft with rubber or plastic heads through to those using brass or ………………………….

4. It’s usually used for flattening, or peining, a ………………………….


Chisels

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Chisels

When using hammers and chisels safety goggles should al-ways be worn.

This is the most common kind of chisel - a flat chisel. It’s made of high-quality steel, and the end is tempered and hardened because it has to be harder than any of the metals you’re likely to want to cut with it. The head of the chisel needs to be softer so it won’t chip when it’s hit with a hammer.

This is a cross-cut chisel. It’s called ‘cross cut’ because the sharpened edge is across the blade width. This chisel narrows down along the stock, so it’s good for getting in grooves. It’s used for cleaning out or even making key-ways. The flying chips of metal should always be directed away from the user.

The gasket scraper is not a true chisel. It has a hardened, sharpened blade and it’s designed to remove a gasket with-out damaging the sealing face of the component. The scraper should be kept sharp to make it easy to remove all traces of the old gasket and sealing compound.


Name Date Class


Summary The most common type of chisel is the flat chisel. You should al-ways wear safety goggles when working with chisels.


Chisels

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Name Signature Date

Score / 3

1. This is a cross-cut chisel. It’s called ‘cross cut’ because the sharpened edge is across the blade

………………………….

2. The most common kind of chisel is a flat chisel. It’s made of high-quality steel, and the end is tempered and

………………………… because it has to be harder than any of the metals you’re likely to want to cut with it.

3. The scraper should be kept ………………………… to make it easy to remove all traces of the old gasket and sealing compound.


Saws

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Saws

Hacksaws are a common workshop tool. The frames come in a range of shapes and sizes. For any given frame there’s a range of available hacksaw blades to cope with different materials and situations.

The hacksaw frame can be adjusted to take differ-ent blade lengths and when the blade is placed in the frame and it is tightened to the correct tension by a tensioning device such as a wing nut.

The hacksaw blade must be of the right pitch which is deter-mined by the number of teeth in an inch of blade. A blade with many teeth per inch has a fine pitch, one with few teeth per inch has a coarse pitch.

The saw blade should be inserted into the frame so that it only cuts on the forward stroke. This is because the teeth gather the metal being removed and can only get rid of it when they come clear of the cut. If a blade cutting through a thick section of metal has too many teeth, in other words the pitch is too fine, they can clog up and stop cutting.

On the other hand, when cutting a piece of sheet metal, if the blade is too coarse the saw teeth could be stripped off of the blade at it try’s to cut.

As a rough guide you can determine the correct blade (and number of teeth) by laying the blade across the section being cut. Normally, at least 3 teeth should touch the metal at that point. This will ensure that the blade can do its job.

After the job is done, the tension on the blade should be loosened, to prevent the frame from distorting over time.

Cutting large holes in panel steel or thin sheet metal is done by a hole saw. The drill in the center locates the saw accu-rately and leads it into the surface.


Name Date Class


Summary Hacksaws are a common workshop tool. The frames come in a range of shapes and sizes. For any given frame there’s a range of available hacksaw blades to cope with different materials and situations.


Saws

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Repetitive cutting through thick sections of material can be hard work, unless you have an abrasive cut-off saw.

These are rated in different sizes, usually from about 250 mil-limeters to 500 millimeters or 9 3⁄4 inches to 19 1⁄2 inches. That refers to the largest diameter cutting wheel that should be fitted to them.

This is a powerful tool and it demands every precaution. Wear protective clothing, with nothing hanging out or loose, espe-cially long hair. You should cover long hair with a snood cap and of course, wear safety glasses or a full-face shield. The guard on the saw should be properly in place, and the power cord well away from the cutting wheel. Flying Sparks are nor-mal when using this saw, the range of these should be limited by placing a safety screen around the job.

1. After the job is done, the tension on the blade should be …………………………, to prevent the frame from distorting over time.

2. Flying ………………………… are normal when using this saw, the range of these should be limited by placing a safety screen around the job.

3. The saw blade should be inserted into the frame so that it only cuts on the ………………………… stroke.


Name Signature Date

Score / 3


Screw-drivers

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Screw-drivers

The correct screwdriver to use depends on the type of slot or recess in the head of the screw or bolt, and how accessible it is.

Most screwdrivers can’t grip as securely as spanners, so it’s very important to match the tip of the screwdriver exactly with the slot or recess in the head of a fastener. Otherwise the tool might slip, damaging the fastener, and worse still, you.

When using a screwdriver, always check where the screw-driver blade can end up if it slips off the head of the screw. A screwdriver can’t tell the difference between a piece of steel, and a piece of you.

The most common screwdriver has a flat tip, or blade, which gives it the name, blade screwdriver. It’s easy to see the blade should be almost as wide as the slot in the fastener so that twisting force applied to the screwdriver is transferred right out to the edges of the head where it has most effect.

Not so easy to see, is that the blade should be a snug fit in the slot of the screw head. Then the twisting force is applied even-ly along the sides of the slot. This guards against the screw-driver suddenly chewing a piece out of the slot, and slipping, just when most force is being exerted.

If viewed side-on , the blade should taper until the very end where the tip fits in the slot. If the tip of the blade isn’t clean and square, it should be reshaped.

When you use a blade screwdriver, make sure you support the shaft with your free hand as you turn it. This helps keep the blade square on to the slot and centered. Slipping screwdrivers are a common source of damage and injury in workshops.


Name Date Class


Summary The correct screw-driver to use depends on the type of slot or re-cess in the head of the screw or bolt, and how accessible it is.


Screw-drivers

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A screw or bolt with a star-shaped recess needs a Phillips or a Pozidrive screwdriver. The star-shaped slot holds the tip of the screwdriver securely on the head.

The Phillips tip fits a tapered recess while the pozidrive fits into slots with parallel sides in the head of the screw. Both a Phillips or Pozidrive head can be pushed and twisted with more confidence, but again the screwdriver must be the right size. This is simplified with these 2 types of screwdriver be-cause 4 sizes are enough to fit almost all fasteners with this sort of screw head.

The Allen key is designed to be a snug fit in screws with a socket head.

The socket and the key are hexagonal in shape, and there’s a correct sized key for every socket, so Allen keys come in sets. They can come in either the metric or Imperial system, and are categorized in millimeters or fractions of an inch, accord-ing to the distance across opposite flats of the hexagon.They give the best grip on a screw or bolt of all the drivers, and their shape makes them good at getting into tight spots.

The offset screwdriver fits into spaces where nothing else will, and where there’s not much room to turn it. The two tips look identical but one’s at 90 degrees to the other. This is because sometimes there’s sometimes only room to make a quarter turn of the driver. That is why the driver has two blades on op-posite ends so that offset ends of the screwdriver can be used alternately.


Screw-drivers

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The ratchet is a popular screwdriver handle that usually comes with a selection of flat and Phillips tips. It has a ratchet inside that turns the blade in only one direction depending on how the slider is set. When set, a screw can be undone without removing the tip of the blade from the head of the screw.

Equally, when set in the opposite direction screws can be inserted just as easily.

This is an impact driver . A screw or a bolt that’s rusty or over tightened needs a tool that can apply more force than the other members of this family.

The impact driver takes a variety of tips. Choose the right one for the screw head, fit the tip in place, and then tension it in the direction it has to turn. A sharp blow with the hammer breaks the screw free, and it can be unscrewed.

1. A screw or a bolt that’s ………………………… or over tightened needs a tool that can apply more force than the other members of this family.

2. They can come in either the metric or Imperial system, and are categorized in millimeters or fractions of an inch,

according to the distance across opposite ………………………… of the hexagon.

3. If viewed side-on, the blade should taper until the very end where the tip fits in the slot. If the tip of the blade

isn’t clean and square, it should be ………………………….

4. The Phillips tip fits a ………………………… recess while the pozidrive fits into slots with parallel sides in the head of the screw.


Name Signature Date

Score / 4

HA031-2


Vices & clamps

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Vices & clamps

The bench vice is a useful tool for holding anything that can fit into the jaws and needs sawing, filing, or chiseling.

The jaws are serrated to give extra grip and they’re also very hard, which means that when the vice is done up tightly, the jaws can mark whatever they’re gripping. To prevent this a pair of soft jaws can be fitted whenever the danger of damage arises. They’re usually made of aluminum or some other soft metal.

Some things can be awkward to grip vertically in a plain vice, so there’s another style called an offset vice.


Name Date Class


Summary The bench vice is a plain vice that will hold anything that needs sawing, filing, or chiselling. The G-clamp holds parts together while they’re being worked on.


Vices & clamps

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These slots in the work table of this drill are designed for a drill vice. To hold something firmly and drill it accurately, it has to be secured in the jaws of the vice. The vice can me moved on the bed until the precise drilling point is located, and then tightened down by bolts to fix the drill vice in place during drilling.

A G-clamps name comes from its shape. It can hold parts together while they’re being assembled, or maybe drilled or welded. It can reach around awkwardly shaped pieces that won’t fit in a vice. And it’s portable so it can be taken to the work

1. Some things can be awkward to grip vertically in a plain vice, so there’s another style called an

………………………… vice.

2. The jaws are ………………………… to give extra grip and they’re also very hard, which means that when the vice is done up tightly, the jaws can mark whatever they’re gripping.

3. A G-clamp’s name comes from its………………………….


Name Signature Date

Score / 3


Spanners

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Spanners

Spanners (which are also often known as wrenches in some countries) will only do a job properly if it’s the right size for the nut or the bolt to be turned.

The size used to describe a spanner/wrench is the distance across the flats of the nut or bolt to be turned. There are two systems in common use, metric, in millimeters, and impe-rial, in inches. Each of the systems has a range of spanners/wrenches especially made for each one. The systems can be identified on the spanner/wrench by either a number for met-ric spanners, or a fraction followed by A/F.

Another system once widely used in the United Kingdom was the Whitworth system. It used fractions but they did not refer to the distance across the flats of the fastener. Some older British and Australian machines use Whitworth-size fasteners. Some Whitworth sizes are not interchangeable with metric or Imperial systems.

There are many types of spanners/wrenches.

Choosing the correct one to use to do the job usually depends on two things: How tight is the fastener? In other words how much force is going to be applied to it, and, how accessible is it? - how much room is there to get the spanner onto the fastener, and then turn it.

When being used it’s always possible a spanner/wrench will slip. Always try to anticipate what will happen if it does before putting a lot tension onto it. If possible, always pull a spanner/wrench towards you rather than pushing it away.

Ring spanners grip a fastener at the corners just like a socket spanner, just the sort of grip that is needed if a nut or bolt is very tight. Ring spanners have different sized heads at each end. They aren’t as convenient as sockets but can fit into places that a socket can’t. One disadvantage of the ring span-ner is that it can be awkward to use once the nut or bolt’s been loosened.


Name Date Class


Summary There are many types of spanners. The most common are the ring spanner, open end spanner & the combination spanner. Spanners will only do a job properly if it’s the right size for the nut or the bolt to be turned.


Spanners

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Open end spanners/wrenches slip easily and quickly onto fasteners, and that’s particularly important for nuts and bolts in awkward places. The angle on the head allows it to be used in two different positions. While an open-end spanner often gives the best access to a fastener, if it’s extremely tight the open-end shouldn’t be used as this type of spanner/wrench only grips across two flats. If the jaws flex slightly or the flats don’t fit tightly between them, the spanner can suddenly slip when force is applied.

The best way is to use a ring spanner to break such a bolt or nut free, then the open-end. The open-end spanner should only be used on fasteners that are no more than firmly tight-ened.

The combination spanner/wrench provides the user with the best features of each of the other types. It has a ring on one end for gripping and breaking the fastener’s hold, and an open ended spanner of the same size on the other end.

A variation on the open end head is the flare nut spanner. It gives a better grip because the flats meet on 5 sides, not 2. The open 6th side lets the spanner be used on nuts and fit-tings associated with pipes and tubing. Don’t use the flare-nut spanner on extremely tight fasteners as the jaws may spread, damaging the nut.


Spanners

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There is another type of universal adjustable open end span-ner/wrench in use. Usually referred to as a shifting spanner/wrench or simply “shifters”, the lower jaw can be moved to fit any fastener size within the spanner range. Shifting spanners should only be used if the correct sized spanner is not avail-able. Both the fastener and spanner could be damaged if they are used on really tight bolts or nuts.

1. Always try to ………………………… what will happen if it does before putting a lot tension onto it.

2. It has a ring on one end for gripping and ………………………… the fastener’s hold, and an open ended spanner of the same size on the other end

3. There are many types of spanners/wrenches. Choosing the correct one to use to do the job usually depends on two things: 1. How ………………………… is the fastener? In other words how much force is going to be applied to it?

4. 2. How …………………………is the fastener? - how much room is there to get the spanner onto the fastener, and then turn it.

5. The size used to describe a spanner/wrench is the distance across the ………………………… of the nut or bolt to be turned.


Name Signature Date

Score / 5


Sockets & accessories

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Sockets are a good choice where the top of the fastener is reasonably accessible. The socket fits onto it snugly and grips it on all 6 corners and is the type of grip needed on any nut or bolt that’s extremely tight.

Sockets also come in deep wall sizes . These are ideal for removing or tightening spark plugs or nuts screwed on to long protruding threads.

There is also a special socket that only has 6 flats instead of the common 12 point design. It’s specially made for impact wrenches that exert a lot more pressure than turning sockets by hand. Socket spanners always need an attachment to turn them. This is done by a range of accessories, many of which are included in socket tool sets.


Name Date Class


Summary Sockets are a good choice where the top of the fastener is reason-ably accessible. The socket fits onto it snugly and grips it on all six corners and is the type of grip needed on any nut or bolt that’s extremely tight.



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The connection between the socket and accessory is made by a square drive. The larger the drive, the heavier and bulkier the socket.

The quarter-inch drive is for small work in difficult areas. The three-eighth drive handles a lot of general work where torque requirements are not too high. The half-inch drive is for all-round service. The three-quarter inch drive is for large work with high torque settings.

Many fasteners are located in positions where access can be difficult. Many lengths of extensions are available to bring the drive point out to where a handle can be attached.

A universal joint can be used with an extension and takes the turning force that’s to be applied through an angle.

A speed brace is the fastest way to spin a nut on or off a thread by hand, but it can’t apply much torque to the nut, so it’s mainly used to remove a nut that’s already been loosened, or to run the nut onto the thread until it begins to tighten.



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The most common socket handle, the ratchet, makes easy work of tightening or loosening a nut where not a lot of pres-sure is involved. It can be set to turn in either direction and it doesn’t need much room to swing it. It’s built to be conve-nient, not super-strong, so too much pressure could damage it.

For heavier tightening or loosening, an adjustable offset handle or breaker bar , gives the most leverage.

When that’s not available a sliding tee-handle may be more useful. Both hands can be used, and the position of the tee piece is adjustable to clear any obstructions to turning it.



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Name Signature Date

Score / 3

1. Many lengths of ………………………… are available to bring the drive point out to where a handle can be attached.

2. A ………………………… brace is the fastest way to spin a nut on or off a thread by hand, but it can’t apply much torque to the nut, so it’s mainly used to remove a nut that’s already been loosened, or to run the nut onto the thread until it begins to tighten.

3. There is also a special socket that only has 6 flats instead of the common 12 point design. It’s specially made for

………………………… wrenches that exert a lot more pressure than turning sockets by hand.


Pliers

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Pliers

Safety first:

• When applying pressure to pliers, make sure your hands aren’t greasy, otherwise, sooner or later, they’re going to slip.

• Select the right type and size of pliers for the job. As with most tools - if you have to exert almost all your strength to get something done, then you’re either using the wrong tool, or you’re doing it incorrectly.

• If the pliers lets go, you’re going to get hurt. At the very least you’ll damage the tool, and the work.

• Pliers get a lot of hard use in the workshop, so they do get worn and damaged. That makes them inefficient and even dangerous. Always check the state of all workshop tools on a regular basis.

Combinationpliers are made from 2 pieces of high carbon or alloy steel. They pivot together so that any force ap-plied to the handles is multiplied in the strong jaws.

Some pliers provide a powerful grip on objects, others are designed to cut. Combination pliers can do both - that’s why they’re the most common type.

There are two surfaces for gripping flat or rounded objects, and two pairs of cutters. The cutters in the jaws should be used for softer materials that won’t damage the blades.

The cutters next to the pivot can shear through hard, thin materials, like steel wire or pins.

Most pliers are limited by their size in what they can grip.

Beyond a certain point the handles are spread too wide, or the jaws can’t open wide enough, but these multi-grips overcome that with a moveable pivot.

A pair of multi-grips can get a comfortable grip on a range of objects, and there are 2 surfaces for things that are flat or round.

Student/Interninformation:

Name Date Class


Summary Combination pliers are made from two pieces of high carbon or al-loy steel. They pivot together so that any force applied to the han-dles is multiplied in the strong jaws. Most pliers are limited by their size in what they can grip. It is important to select the right type and size of pliers for the job.


Pliers

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Vicegrips are general purpose pliers. Put an object between the jaws, turn the screw until the handles are almost closed, then squeeze them together to lock shut. They can also be used as temporary clamps in case a free hand is needed else-where.

There are a few specialized pliers in most workshops:

Long-nosedpliers can reach tight spots that others can’t.

Flat-nosedpliers, have an end that is flat and square on the the end or nose, while on the combination pliers the end is rounded. A flat nose makes it possible to bend wire, or even a thin piece of sheet steel accurately along a straight edge.


Pliers

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Circlippliers have metal pins that fit in holes in a circlip. Squeezing the pliers compresses the circlip and fits it in its groove. There’s also a special pair of externalcirclips (right) that are sprung to push them open.

This type of cutters are called Nippers, or pincer pliers. They have a cutting edge at right angles to their length. They are designed to get a grip on and cut through anything sticking out from a surface. Rolling them on the curve of the jaws gives leverage too.

Sidecutters work with any length, on things like wire or a steel pins. They’re the most common cutters in the toolbox but they shouldn’t be used on hard or heavy gauge materi-als.


Pliers

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Boltcutters cut heavy wire, rods, and bolts. Their compound joints and long handles give the leverage and cutting pressure that’s needed for heavy gauge materials.

Tinsnips are the nearest thing in the toolbox to a pair of scissors. They can cut thin sheet metal, and lighter versions make it easy to follow the outline of gaskets. Most snips come with straight blades but if there’s an unusual shape to cut there is a pair with left or right hand curved blades.

Aviationsnips are designed to cut soft metals. They’re easy to use because the handles are spring loaded open and double pivoted for extra leverage.


Pliers

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Supervisor/Instructorinformation:

Name Signature Date

Score/5

1. Bolt cutters cut heavy wire, rods, and bolts. Their ………………………… joints and long handles give the leverage and cutting pressure that’s needed for heavy gauge materials.

2. Beyond a certain point the handles are spread too wide, or the jaws can’t open wide enough, but these multi-

grips overcome that with a moveable ………………………….

3. They can also be used as temporary ………………………… in case a free hand is needed elsewhere.

4. …………………………snips are designed to cut soft metals.

5. They are designed to get a grip on and cut through anything sticking out from a surface. ………………………… them on the curve of the jaws gives leverage too.


Wrenches

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Wrenches

A torque wrench is also known as a tension wrench.

It is designed to tighten bolts and nuts using the drive on the end which takes any sockets and accessories found in an ordinary socket set. It is used to tighten fasteners, to a pre de-termined tension (torque) by the use of a movable scale that allows how tightly the nut or bolt is being done up.

Whilst manufacturers don’t specify torque settings for every nut and bolt, when they do, it’s important, and that’s why the torque wrench is such an important tool.

The pipe wrench grips pipes and tubes and it can exert a lot of force to turn them. Putting more pressure on this wrench tightens its grip more and more. The jaws are hardened and serrated, and increasing the pressure also increases the risk of marking or even gouging metal from the pipe.


Name Date Class


Summary A torque wrench tightens bolts and nuts. A pipe wrench grips pipes and tubes. Other specialised wrenches include the wheel brace & oil filter removing tool.


Wrenches

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A wheel brace is a specialized wrench. This model has 4 dif-ferent sockets, 1 on each arm. Never hit or jump on a wheel brace when loosening wheel nuts. If the brace won’t remove them, use an impact tool. When using the wheel brace, the force provided with your hands is adequate to secure the nuts properly.

This specialized wrench is an oil filter removing tool, which gives that extra leverage when oil filters are tight.

1. The jaws are hardened and …………………………, and increasing the pressure also increases the risk of marking or even gouging metal from the pipe.

2. This specialized wrench is an oil filter removing tool, which gives that extra ………………………… when oil filters are tight.

3. It is used to tighten fasteners, to a ………………………… tension (torque) by the use of a movable scale that allows how tightly the nut or bolt is being done up.


Name Signature Date

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Files

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Files

Files are often sold without handles, but they shouldn’t be used until a handle of the right size has been fitted. The handle should be checked before use. It can come loose, and it may need a sharp rap to tighten it up.

Clean hands will help avoid slipping. Hands should always be kept away from the surface of the file and the metal that’s being worked on. Filing can produce small slivers of metal which can be difficult to remove from a finger or hand, and acids and moisture from the skin can cause corrosion.

Depending on how hard or soft a material is, a special file may be needed. It’s no good trying to file something if the file is softer than what is being filed - softer metals like copper and aluminum can clog a conventional file.

What makes one file different from another is not just it’s shape but how much material it’s designed to remove with each stroke. That depends on the teeth. The following are both flat files, the most common general purpose type, but their teeth are different.

The teeth on this coarse grade file (left) are longer, with a greater space between them. Filing this piece of mild steel removes a lot of material with each stroke. A coarse file leaves a rough finish.

On the right is a flat file, but its shorter teeth remove much less material on each stroke, and the finish is much smoother.

On a job, the coarse file is used first to remove material quickly, then a smoother file gently removes the last of it and leaves a clean finish to the work.

The full list of grades in flat files, from rough to smooth, is:

• rough

• coarse bastard

• second cut

• smooth, and

• dead smooth

Some flat files are available with one smooth edge, called safe edge files. They allow filing up to an edge without damaging it. Flat files are fine on straightforward jobs but files need to be able to work in some awkward spots as well.


Name Date Class


Summary There are many different types of files. What makes one file differ-ent from another is not just it’s shape but how much material it’s designed to remove with each stroke.


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A warding file is thinner than normal, for working in narrow slots.

A square file has teeth on all 4 sides, so you can use it in a square or rectangular hole.

A square file can make the right shape for a squared metal key to fit in a slot. This is a three square file. It’s triangular in section, so it can get into internal corners.

Curved files are either half-round, or round. This is a half round. Its shal-low convex surface can file in a concave hollow, or in an acute internal corner. The fully round file, sometimes called a rat-tail file, can make holes bigger. Or it can file inside a concave surface with a tight radius.


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Files should be cleaned after use. If they’re clogged, they can be cleaned by a tool that’s really part of the family called a filecard or filebrush.

This is a thread file. It cleans clogged or distorted threads. It has 8 dif-ferent surfaces that match different thread dimensions so the right face must be used.

1. If they’re clogged, they can be cleaned by a tool that’s really part of the family called a filecard or

………………………….

2. It has 8 different surfaces that match different thread ………………………… so the right face must be used.

3. The full list of grades in flat files, from rough to smooth, is:

• rough

• coarse bastard

• ………………………… cut

• smooth, and

• dead smooth

4. A coarse file leaves a ………………………… finish..


Name Signature Date

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Torque wrenches

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Torque wrenches

This is a torque wrench. It tightens bolts and nuts using the drive on the end, which takes any sockets and accessories.

What makes this a special way to tighten fasteners is a scale that shows how tightly the nut or bolt is being done up.

This head bolt is being tightened to a specified torque recom-mended by the manufacturer, as being tight enough to ensure that the nut won’t come loose, and the parts are being held together firmly, but not so tight as to risk breaking the bolt or stripping its threads.

Manufacturers don’t specify torque settings for every nut and bolt, but when they do, it’s important, and that’s why the torque wrench is such an important tool.

1. Manufacturers don’t specify ………………………… settings for every nut and bolt, but when they do, it’s important, and that’s why the torque wrench is such an important tool.

2. It tightens bolts and nuts using the ………………………… on the end, which takes any sockets and accessories.

3. What makes this a special way to tighten fasteners is a ………………………… that shows how tightly the nut or bolt is being done up.


Name Date Class



Name Signature Date

Score / 3

Summary The torque wrench tightens bolts and nuts to a specified torque recommended by the manufacturer. Whilst manufacturers don’t specify torque settings for every nut and bolt,when they do, it’s im-portant, and that’s why the torque wrench is such an important tool.


handout activity: ha027 - dysart high school ball-peen is used a great deal. the ball-pein hammer...

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