Basic hand tools

HA027-2

Handout Activity: HA027

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Basic hand tools

Summary
Choose the right tool for the job. Otherwise you could damage the
part you are working on, the tool, or yourself.
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 arent 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 fasteners. 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. Youll
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 workshops
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 youre striking. The hammer face MUST ALWAYS BE SOFTER than the
part youre 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. Its usually used for flattening, or peening,
a rivet. If you cant 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 its 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 youll use channel lock pliers. Theyre 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.

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Basic hand tools

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1. If you cant 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 youll use lock pliers.

3. The hammer face MUST ALWAYS BE than the part youre hammering.
4. The ball-peen hammer gets its name from the ball on the rounded face. Its usually used for flattening, or

, a rivet.

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

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Hammers

HA028-2

Handout Activity: HA028

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Hammers
Summary
The most common hammer in an automotive workshop is the ball
pein or engineers hammer. The soft-face & deadblow hammers are
also used.faces.
The most common hammer in an automotive workshop is the ball pein or engineers 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.
Its usually used for flattening, or peining, a rivet.
The hammer should always match the size of the
job and its better to use one thats 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 its 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, its time to use the lump
hammer. Its like a small mallet, with two square faces made of high carbon
steel. Its 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.
Its 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. Its 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 its hollow with lead shot inside. The lead absorbs the
blow.

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Hammers

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1. The most common mallet in the workshop has a head made of hard rubber. Its 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 its

hollow with lead shot inside.
3. Some are very soft with rubber or plastic heads through to those using brass or .
4.

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Its usually used for flattening, or peining, a .

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Chisels

HA029-2

Handout Activity: HA029

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Chisels
Summary
The most common type of chisel is the flat chisel. You should always wear safety goggles when working with chisels.
When using hammers and chisels safety goggles should always be worn.

This is the most common kind of chisel - a flat chisel. Its made
of high-quality steel, and the end is tempered and hardened
because it has to be harder than any of the metals youre likely
to want to cut with it. The head of the chisel needs to be softer
so it wont chip when its hit with a hammer.

This is a cross-cut chisel. Its called cross cut because the

sharpened edge is across the blade width. This chisel narrows
down along the stock, so its good for getting in grooves. Its
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 its designed to remove a gasket without 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.

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Chisels

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1. This is a cross-cut chisel. Its called cross cut because the sharpened edge is across the blade

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

because it has to be harder than any of the metals youre 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.

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Saws

HA030-2

Handout Activity: HA030

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Saws
Summary
Hacksaws are a common workshop tool. The frames come in a
range of shapes and sizes. For any given frame theres a range of
available hacksaw blades to cope with different materials and
situations.
Hacksaws are a common workshop tool. The frames
come in a range of shapes and sizes. For any given
frame theres a range of available hacksaw blades to
cope with different materials and situations.
The hacksaw frame can be adjusted to take different 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 determined 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 trys 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 accurately and leads it into the surface.

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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 millimeters to 500 millimeters or 9 34 inches to 19 12 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, especially 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 normal 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.

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Screw-drivers

HA031-2

Handout Activity: HA031

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Screw-drivers
Summary
The correct screw-driver to use depends on the type of slot or recess in the head of the screw or bolt, and how accessible it is.
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 cant grip as securely as spanners, so its
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 screwdriver blade can end up if it slips off the head of the screw. A
screwdriver cant 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. Its 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 evenly along the sides of the slot. This guards against the screwdriver 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 isnt 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.

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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 because 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 theres 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, according 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 theres not much room to turn it. The two tips look
identical but ones at 90 degrees to the other. This is because
sometimes theres sometimes only room to make a quarter
turn of the driver. That is why the driver has two blades on opposite ends so that offset ends of the screwdriver can be used
alternately.

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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 thats 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 thats 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

isnt 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.

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Vices & clamps

HA032-2

Handout Activity: HA032

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Vices & clamps

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
theyre being worked on.

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 theyre also very
hard, which means that when the vice is done up tightly, the
jaws can mark whatever theyre gripping. To prevent this a
pair of soft jaws can be fitted whenever the danger of damage
arises. Theyre usually made of aluminum or some other soft
metal.

Some things can be awkward to grip vertically in a plain vice,

so theres another style called an offset vice.

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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 theyre being assembled, or maybe drilled or
welded. It can reach around awkwardly shaped pieces that
wont fit in a vice. And its portable so it can be taken to the
work

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

vice.

2. The jaws are to give extra grip and theyre also very hard, which means that when the vice

is done up tightly, the jaws can mark whatever theyre gripping.
3. A G-clamps name comes from its.

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Spanners

HA033-2

Handout Activity: HA033

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Spanners
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 its the right size for the nut or the bolt
to be turned.
Spanners (which are also often known as wrenches in some
countries) will only do a job properly if its 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 imperial, 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 metric 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 its 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 arent as convenient as sockets but can fit into
places that a socket cant. One disadvantage of the ring spanner is that it can be awkward to use once the nut or bolts been
loosened.

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Open end spanners/wrenches slip easily and quickly onto
fasteners, and thats 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 its extremely tight the
open-end shouldnt be used as this type of spanner/wrench
only grips across two flats. If the jaws flex slightly or the flats
dont 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 tightened.

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 fasteners 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 fittings associated with pipes and tubing. Dont use the flare-nut
spanner on extremely tight fasteners as the jaws may spread,
damaging the nut.

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There is another type of universal adjustable open end spanner/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 available. 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 fasteners 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.

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Sockets & accessories

HA034-2

Handout Activity: HA034

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Sockets & accessories

Summary
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
six corners and is the type of grip needed on any nut or bolt thats
extremely tight.

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 thats 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. Its 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.

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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 allround 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 thats 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 cant apply much torque to the nut, so
its mainly used to remove a nut thats 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 pressure is involved. It can be set to turn in either direction and
it doesnt need much room to swing it. Its built to be convenient, 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 thats 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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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 cant apply much

torque to the nut, so its mainly used to remove a nut thats 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. Its specially made for

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

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Pliers

HA035-2

Handout Activity: HA035

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Pliers
Summary
Combination pliers are made from two pieces of high carbon or alloy steel. They pivot together so that any force applied to the handles 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.
Safety first:
When applying pressure to pliers, make sure your hands
arent greasy, otherwise, sooner or later, theyre 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 youre either using
the wrong tool, or youre doing it incorrectly.

If the pliers lets go, youre going to get hurt. At the very
least youll 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.

Combination pliers are made from 2 pieces of high carbon or alloy steel. They pivot together so that any force applied 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 thats why theyre 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 wont 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 cant open wide enough, but these multigrips 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.

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Vice grips 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 elsewhere.
There are a few specialized pliers in most workshops:

Long-nosed pliers can reach tight spots that others cant.

Flat-nosed pliers, 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.

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Circlip pliers have metal pins that fit in holes in a circlip. Squeezing the pliers compresses the circlip and fits it in
its groove. Theres also a special pair of external circlips (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.

Side cutters work with any length, on things like wire or a

steel pins. Theyre the most common cutters in the toolbox
but they shouldnt be used on hard or heavy gauge materials.

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Bolt cutters cut heavy wire, rods, and bolts. Their compound
joints and long handles give the leverage and cutting pressure
thats needed for heavy gauge materials.

Tin snips 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 theres an unusual shape to
cut there is a pair with left or right hand curved blades.

Aviation snips are designed to cut soft metals. Theyre easy to

use because the handles are spring loaded open and double
pivoted for extra leverage.

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Pliers

HA035-2

1. Bolt cutters cut heavy wire, rods, and bolts. Their joints and long handles give the leverage

and cutting pressure thats needed for heavy gauge materials.
2. Beyond a certain point the handles are spread too wide, or the jaws cant 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.

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Wrenches

HA036-2

Handout Activity: HA036

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Wrenches
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.

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 determined tension (torque) by the use of a movable scale that
allows how tightly the nut or bolt is being done up.
Whilst manufacturers dont specify torque settings for every
nut and bolt, when they do, its important, and thats 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.

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Wrenches

HA036-2

A wheel brace is a specialized wrench. This model has 4 different sockets, 1 on each arm. Never hit or jump on a wheel
brace when loosening wheel nuts. If the brace wont 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.

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20070814 Page 

Files

HA037-2

Handout Activity: HA037

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Files
Summary
There are many different types of files. What makes one file different from another is not just its shape but how much material its
designed to remove with each stroke.
Files are often sold without handles, but they shouldnt 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
thats 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. Its 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 its
shape but how much material its 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.

2009 Jones and Bartlett Publishers LLC

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Files

HA037-2

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. Its triangular in section, so it can get into
internal corners.

Curved files are either half-round, or round. This is a half round. Its shallow 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

HA037-2

Files should be cleaned after use. If theyre clogged, they can be cleaned
by a tool thats really part of the family called a filecard or filebrush.
This is a thread file. It cleans clogged or distorted threads. It has 8 different surfaces that match different thread dimensions so the right face
must be used.

1.

If theyre clogged, they can be cleaned by a tool thats 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.

Score

A coarse file leaves a finish..

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Torque wrenches

HA038-2

Handout Activity: HA038

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Torque wrenches
Summary
The torque wrench tightens bolts and nuts to a specified torque
recommended by the manufacturer. Whilst manufacturers dont
specify torque settings for every nut and bolt,when they do, its important, and thats why the torque wrench is such an important tool.
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 recommended by the manufacturer, as being tight enough to ensure
that the nut wont 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 dont specify torque settings for every nut
and bolt, but when they do, its important, and thats why the
torque wrench is such an important tool.

1. Manufacturers dont specify settings for every nut and bolt, but when they do, its

important, and thats 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.

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