Architect in Residence

Gradient
Thursday 14
th
Aug
Period 1 3
Overview
Students will be divided into a number of task groups to carry out a specific activity in the assembly
line. Each group must have a workshop authorised student to carry out tasks that require power tools.
Groups will be divided as follows:
1: Cutting aluminium sheet into strips
2: Cutting and shaping plywood bases (scroll saw)
3: Cutting aluminium extrusion to size
4: Drilling holes into aluminium extrusion (metal pedestal drill)
5: Drilling holes into aluminium sheet (pedestal drill)
6: Drilling holes into plywood bases (pedestal drill)
7: Riveting aluminium extrusion to plywood base
8: Bending aluminium extrusion into curves
9: Bending and riveting aluminium sheet to plywood base

Task Breakdown
1: Cutting aluminium sheet into strips
The aluminium sheet needs to be marked out with a whiteboard marker and long ruler into strips that
are 30x450mm
These are then cut to size on the step guillotine.

*Send the cut strips to 5: Drilling holes into aluminium sheet.
2: Cutting and shaping plywood bases
Mark out with pencil an area of 380x800mm and cut along this with a scroll saw. (If a teacher is
available they might use the band saw or table saw instead)
Use a plane to straighten any crooked edges
Use the disc sander to sand the corners round for a more aesthetic look.
*Send the plywood sheets to 6: Drilling holes into plywood bases.
3: Cutting aluminium extrusion to size
Mark out with a metal scribe lengths of aluminium extrusion at 800mm long.
Hold the extrusion in a vice and use a hack saw to cut through along the mark.
Use a metal file to smooth away sharp edges.
*Send aluminium extrusion to 4: Drilling holes into aluminium extrusion.

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4: Drilling holes into aluminium extrusion
A single hole needs to be drilled through the centre of both ends of the aluminium extrusion, about
10mm in from the ends. Make sure the correct size drill bit has been provided.

*Send extrusion to 6: Drilling holes into plywood bases
5: Drilling holes into aluminium sheet
A single hole needs to be drilled through the centre of both ends of the aluminium strip about 10mm
in from the end.
A third hole needs to be drilled through the centre of one end of the aluminium strip exactly 70mm in
from the end.

*Send aluminium strips to 9: Bending and riveting aluminium sheets to plywood base

6: Drilling holes into plywood bases
A total of 6 holes needs to be drilled into the plywood bases.
The first four need to be evenly spaced around the long sides where the base will be hung from.
Approximately 100 150mm in from the end, and 10mm in from the side. Mark all four out in pencil
before drilling.






Use the following method for the last two holes.
Step 1: Drill a single hole at one end of the plywood 10mm away from the edge and centred. [at 5]
Step 2: Send base to 7: Riveting aluminium extrusion to plywood base
Step 3: Receive base back with aluminium riveted in on one side, drill final hole through the hole in the
aluminium extrusion on the opposite end.

*Send plywood back to 7: Riveting aluminium extrusion to plywood base
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7: Riveting aluminium extrusion to plywood base
Rivet only one side of the aluminium extrusion to the plywood base.
Send this back to 6: Drilling holes in plywood base.
Receive the plywood back again with the final hole drilled in.
Rivet the aluminium extrusion to the plywood base through the new hole.
*Send plywood to 8: Bending aluminium extrusion into curves.

8: Bending aluminium extrusion into curves
Using a curved surface and in a controlled manner, gently curve the aluminium extrusion so that it
forms a uniform arch.
This can be achieved by bending small amounts along the length of the strip.
DO NOT just bend the strip right in the middle, as this will create a very steep bend rather than a
gentle arch. You will need to start the bend on one end of the strip and move it along each time,
bending as you go.
*Send plywood to 9: Bending and riveting aluminium sheet to plywood base

9: Bending and riveting aluminium sheet to plywood base
In order for the aluminium sheet to hang straight across the curved surface of the plywood, you will
need to bend one end of the aluminium strip at an angle.
Step 1: Hold aluminium strip vertically in front of the curved base
with the single hole at the bottom.

Step 2: Draw a line across the aluminium that follows the curve of the base.


Step 3: Clamp the aluminium strip in a vice with the drawn line parallel and following the mouth edge
of the vice.
Step 4: Fold the aluminium over the vice at 90 degrees so that the bend occurs across the drawn line.
Step 5: Mark halfway between the two holes on the other side of the aluminium strip.
Step 6: Using the vice again, fold the aluminium in half along the marked line so that the holes line up
Step 7: Rivet four aluminium strips to the plywood base along the angled edge.