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CATAPULT CONSTRUCTION Student Name: ______
Please use all safety precautions indicated on the safety handout sheet you previously filled out. NEVER TURN A MACHINE ON WITHOUT HAVING A STAFF MEMBER CHECK YOUR SETUP.
There are many places you can start working on the project. These places are indicated below with a box 1 and START POINT indication. Do not wait to do an operation if there are other operations you can start. Keep this form with you, and as you finish ALL operations listed under a Start Point, place a check in the corresponding box.
1START POINT - AXLE SHAFT
Safety glasses required Gloves required
ROUND ROD
` Obtain a pre-cut 3/8 inch diameter round rod – one end is already prepared as an example.
` Place a mark ½ inch from the unprepared end.
The next 2 processes can be done in any order depending on equipment availability
TOOL: LATHE
Safety glasses required No gloves
Obtain help from one of the staff to use the lathe.
` Using the chuck key, tighten the rod piece into the Lathe with the mark on the unprepared end just showing beyond the chuck jaws.
` Remove the chuck key.
Have one of the staff check the setup.
` Set the Lathe for Forward and turn on the power switch.
` Advance the speed knob from zero to about half speed.
` Using only the large black knob facing toward you, slowly advance the cutting bit into the rod and cut back to the line.
` Turn the black knob to retract the cutting bit clear of the rod end.
` Turn the speed control knob to zero (0) and turn the lathe off.
` Use the chuck key to remove the rod.
TOOL: MILLING MACHINE
Safety glasses required No gloves
Obtain help from one of the staff to use the Milling Machine.
` Clamp the rod into the Milling Machine vise so that it is centered and fits tight into the vise slot.
` The top of the rod should be above the top of the vise about 1/8 of an inch.
Have one of the staff check the setup
` Turn on the milling machine and advance speed knob from 0 to about 1/2 speed.
` Using only the large black knob toward you, advance the cutter bit into the top of the rod to create a slot.
` Reverse the black knob and return the cutter bit to its original location
` Turn off the milling machine by turning the speed knob to 0.
` Remove the rod.
1START POINT - CATAPULT ARM
4Start Point – Flat aluminum ½ inch stock
Safety glasses required Gloves required
` Obtain a piece of flat aluminum ½ inch stock.
` Using a marker and a square, mark the stock 8 inches from one end.
` Place the stock in a vise and cut it at the mark so it is 8 inches long
` Place a line at ¾ of an inch, 1 inch, 1 ¾ inches and 5 ½ inches from one end.
` Place a center punch mark in the center of the 1 inch, 1 ¾ inches and 5 ½ inches line.
Have one of the staff check your piece.
TOOL: ARBOR PRESS
` Rotate the Arbor Press base plate to align the wide slot directly under the press rod.
` Place the arem into the Arbor Press
` With a rod exactly over the line at the ¾ inch location
` Push the ram down to create a slight bend matching the sample piece provided.
TOOL: DRILL PRESS
Safety glasses required No gloves
` Using the drill press with a number 27 drill, drill a hole at both the 1 and the ¾ inch locations.
` Using the drill press with the number 27 drill, drill a hole at the 5 ½ inch location.
` Using an electric hand drill with the counter sink tool, slightly counter sink the hole at the 1 inch location.
` Clamp the arm in a vise and tap the countersunk hole with an 8x32 tap.
Mounting the catapult arm to the axle shaft
Safety glasses required
` Center the hole at the 5 ½ inch location of the catapult arm directly over the center of the axle shaft.
` Using the arbor press, press the catapult arm down into the slot of the axle shaft.
` Take the assembly to the drill set to drill the rod hole.
` Clamp the assembly so the hole in the arm is directly under the drill point.
` Drill down through the arm hole, and then through axle shaft.
` Remove the assembly from the vise.
` Using a 6x32 screw, a star washer, and a nut securely attach the axle shaft to the catapult arm.
1START POINT - FORMING THE CUP WASHER
TOOL: HYDRAULIC FORMING TOOL
Safety glasses required
` Take a fender washer to the hydraulic forming tool.
` Center the washer on top the die piece.
` Close the silver control knob by turning it clockwise.
` Pump the black handle until the washer is formed into a cup.
` Open the silver knob by turning it counterclockwise and
` Press down on the die until you can remove the formed cup washer.
` After the catapult arm is assembled, use an 8x32 screw and less than a drop of thread locker to attach the cup washer to the catapult arm.