2.05 Bench Fitting To Support 206 BM

CONTENTS FOR LEVEL 2 BENCH FITTING MSFI
Unit No 2.05: Producing components using hand fitting techniques pg 2-14
Types of mechanical gauges pg 15-29
Reading a micrometer pg 30-34
The purpose of drilling pg 35 -43
Bracket Job # 1 Freedback and Drawing pg 44-45
Handle Job # 2 Feedback and Drawing pg 46-47
Allen ScrewJob # 3 Feedback and Drawing pg 48-49
Bracket Operation schedule Inspection,Sources Precations pg 50-52
Handle Operation schedule Inspection,Sources Precations pg 53-55
Bracket Operation schedule Inspection,Sources Precations pg 56-58
Unit Questions pg 59-63
2.05 Issue 1 Dec 2018 Page 1 of 61

Performing Engineering Operations
PEO/2.05
Unit No 05: Producing components using hand fitting techniques
Unit Reference Number: J/504/6349 Unit Credit Value: 14 Unit GLH: 64

Unit Summary
This unit covers the skills and knowledge needed to prove the competences required to cover a
broad range of basic hand fitting activities that will prepare the learner for entry into the engineering
or manufacturing sectors, creating a progression between education and employment, or will
provide a basis for the development of additional skills and occupational competences in the
working environment.
The learner will be expected to prepare for the hand fitting activities by obtaining all the necessary
information, documentation, tools and equipment required, and to plan how they intend to carry out
the required fitting activities and the sequence of operations they intend to use. The learner will be
required to select the appropriate equipment to use, based on the operations to be carried out and
the accuracy required.
In producing the components, the learner will be expected to use appropriate tools and equipment
to mark out the material for a range of features to be produced, and then to use hand tools,
portable power tools, and shaping and fitting techniques appropriate to the type of material and
operations being performed. These activities will include such things as hand sawing, band sawing,
filing, drilling, chiselling, threading, scraping, lapping and off-hand grinding. The components
produced will have features that include flat, square, parallel and angular faces, radii and curved
profiles, drilled holes, internal and external threads, and sliding or mating parts.
During, and on completion of, the fitting operations, the learner will be expected to check the quality
of the workpiece, using measuring equipment appropriate to the aspects being checked and the
tolerances to be achieved. The learner will need to be able to recognise fitting defects, to take
appropriate action to remedy any faults that occur and to ensure that the finished workpiece is
within the drawing requirements. On completion of the fitting activities, the learner will be expected
to return all tools and equipment to the correct locations, and to leave the work area in a safe and
tidy condition.
The learner’s responsibilities will require them to comply with health and safety requirements and
organisational policy and procedures for the fitting activities undertaken. The learner will need to
take account of any potential difficulties or problems that may arise with the fitting activities, and to
seek appropriate help and advice in determining and implementing a suitable solution. The learner
will work under a high level of supervision, whilst taking responsibility for their own actions and for
the quality and accuracy of the work that they carry out.
The learner’s knowledge will provide an understanding of their work, and will enable them to apply
appropriate hand fitting techniques safely. The learner will understand the hand fitting process, and
its application, and will know about the equipment, materials and consumables, to the required
depth to provide a sound basis for carrying out the activities to the required specification.
The learner will understand the safety precautions required when using hand fitting techniques, and
when using hand and power tools. The learner will be required to demonstrate safe working
practices throughout, and will understand the responsibility they owe to themselves and others in
the workplace.
Unit specific additional assessment requirements:
In order to rpove their ability to combine different fitting operations, at least one of the
components produced must be of a significant nature, and must have a minimum of five of
the features listed in assessment criteria 1.13.

Unit learning outcomes and assessment criteria – Performance to be Assessed
1.0 Produce components using hand fitting Job Job Job
techniques Reference Reference Reference
1.01 Work safely at all times, complying with health and
safety legislation, regulations and other relevant
guidelines

1.02 Carry out all of the following during the hand fitting
activities:
 adhere to procedures or systems in place for
risk assessment, COSHH, personal protective
equipment (PPE) and other relevant safety
regulations
 follow job instructions, assembly drawings and
procedures
 ensure that all power tool cables, extension
leads or air supply hoses are in a serviceable
condition
 check that all measuring equipment is within
calibration date
 ensure that the components used are free from
foreign objects, dirt or other contamination
 return all tools and equipment to the correct
location on completion of the fitting activities
1.03 Plan the fitting activities before they start them
1.04 Obtain the appropriate tools and equipment for the

hand fitting operations, and check that they are in a
safe and usable condition
1.05 Mark out the components for the required

operations, using appropriate tools and techniques
1.06 Mark out a range of material forms, to include two

of the following:
 square/rectangular (such as bar stock, sheet
material, machined components)
 circular/cylindrical (such as bar stock, tubes,
turned components, flat disks)
 sections (such as angles, channel, tee section,
joists, extrusions)
 irregular shapes (such as castings, forgings,
odd shaped components)
1.07 Use marking out methods and techniques, to

include:
 direct marking using instruments
Plus one more of the following:
 use of templates
 tracing/transfer methods
1.08 Use a range of marking out equipment, to include

all of the following:
 rules/tapes
 dividers/trammels
 scribers
 punches
 scribing blocks
 squares
 protractor

 vernier instruments
1.09 Mark out workpieces which include all of the

following features:
 datum/centre lines
 square/rectangular profiles
 circles
 radial profiles
 linear hole positions
Plus one more from the following:
 angles/angular profiles
 radial hole positions
 allowances for bending
 simple pattern development
1.10 Cut and shape the materials to the required

specification, using appropriate tools and
techniques
1.11 Cut and shape two different types of material from

the following:
 low carbon/mild steel
 high carbon steel
 cast iron
 stainless steel
 aluminium/aluminium alloys
 brass/brass alloys
 plastic/nylon/synthetic
 composite
 other specific material
1.12 Use both of the following hand fitting activities:

 filing
 hand sawing
Plus one more from the following:
 power sawing
 off-hand grinding
 scraping
 chiselling
 lapping
1.13 Produce components which combine different

operations and have features that cover all of the
following:
 flat datum faces
 faces which are square to each other
 curved profiles
 drilled through holes
 reamed holes
 internal threads
 external threads
Plus three more from the following:
 faces that are parallel to each other

 faces angled to each other
 holes drilled to a depth
 chamfers and radii
 counterbore, countersink, or spot face
 sliding or mating parts
1.14 Measure and check that all dimensional and

geometrical aspects of the component are to the
specification
1.15 Use all of the following measuring equipment

during the hand fitting and checking activities:
 external micrometers
 Vernier calliper
 surface finish equipment (such as comparison
plates, machines)
Plus four more of the following:
 rules
 squares
 callipers
 protractors
 depth micrometers
 depth verniers
 feeler gauges
 bore/hole gauges
 slip gauges
 radius/profile gauges
 thread gauges
 dial test indicators (DTI)
 coordinate measuring machine (CMM)
1.16 Carry out the necessary checks for accuracy, to

include all of the following:
 linear dimensions
 flatness
 squareness
 angles
 profiles
 hole position
 hole size/fit
 depths
 thread size and fit
 surface finish
1.17 Produce components to all of the following

standards, as applicable to the process:
 components to be free from false tool cuts,
burrs and sharp edges
 general dimensional tolerance +/- 0.25mm or
+/- 0.010”
 there must be one or more specific dimensional
tolerances within +/- 0.1mm or +/- 0.004”
 flatness and squareness 0.05mm per 25mm or

0.002 per inch
 angles within +/- 1 degree
 screw threads to BS Medium fit
 reamed and bored holes within H8
 surface finish 63 µin or 1.6 µm
1.18 Deal promptly and effectively with problems within

their control, and seek help and guidance from the
relevant people if they have problems that they
cannot resolve
1.19 Leave the work area in a safe and tidy condition on

completion of the fitting activities
2.0 Know how to produce components using hand fitting techniques

Knowledge and understanding are key components of competent performance. Where the
candidate’s knowledge and understanding is not apparent from performance evidence, it must
be assessed by other means and supported by suitable evidence.
If there is any doubt as to what constitutes suitable evidence, the external verifier should be
consulted.
As appropriate record the knowledge assessment criteria response and location of the
evidence for 2.0 using:
O – Oral questioning
W – Written questioning
I – Inferred response (use only during observation)
CD – Company documentation
TC – Technical certificate
Other – Any other agreed assessment method
2.01 Describe the health and safety requirements and safe working practices and procedures
required for the hand fitting activities undertaken
O ---- W ---- I ---- TC ---- CD ---- Other ----
Location of Evidence:
2.02 Describe the importance of wearing appropriate protective clothing and equipment, and of
keeping the work area safe and tidy
O ---- W ---- I ---- TC ---- CD ---- Other ----
2.03 Describe the hazards associated with the hand fitting activities (such as use of power tools,
trailing leads or hoses, damaged or badly maintained tools and equipment, using files with
damaged or poor fitting handles), and how they can be minimized
O ---- W ---- I ---- TC ---- CD ---- Other ----
2.04 Describe the procedure for obtaining the required drawings, job instructions and other
related specifications
O ---- W ---- I ---- TC ---- CD ---- Other ----
2.05 Explain how to use and extract information from engineering drawings and related
specifications (to include symbols and conventions to appropriate BS or ISO standards), in
relation to work undertaken

O ---- W ---- I ---- TC ---- CD ---- Other ----
2.06 Explain how to interpret first and third angle drawings, imperial and metric systems of
measurement, workpiece reference points and system of tolerancing
O ---- W ---- I ---- TC ---- CD ---- Other ----
2.07 Explain how to prepare the materials in readiness for the marking out activities, in order to
enhance clarity, accuracy and safety (such as visually checking for defects, cleaning the
materials, removing burrs and sharp edges, applying a marking out medium)
O ---- W ---- I ---- TC ---- CD ---- Other ----
2.08 Explain how to select and establish a suitable datum; the importance of ensuring that
marking out is undertaken from the selected datum, and the possible effects of working
from a different datum
O ---- W ---- I ---- TC ---- CD ---- Other ----
2.09 Describe the methods of holding and supporting the workpiece during the marking out
activities, and equipment that can be used (such as surface plates, angle plates, vee
blocks and clamps, parallel bars, screw jacks)
O ---- W ---- I ---- TC ---- CD ---- Other ----
2.10 Describe the use of marking out conventions when marking out the workpiece (including
datum lines, cutting guidelines, square and rectangular profiles, circular and radial profiles,
angles, holes which are linearly positioned, boxed and on pitch circles)
O ---- W ---- I ---- TC ---- CD ---- Other ----
2.11 Describe the ways of laying out the marking out shapes or patterns to maximise use of
materials
O ---- W ---- I ---- TC ---- CD ---- Other ----
2.12 Describe the need for clear and dimensional accuracy in marking out to specification and
drawing requirements

O ---- W ---- I ---- TC ---- CD ---- Other ----
2.13 Explain how to set and adjust tools (such as squares, protractors and Verniers)
O ---- W ---- I ---- TC ---- CD ---- Other ----
2.14 Describe the importance of using tools only for the purpose intended; the care that is
required when using the equipment and tools; the proper way of storing tools and
equipment between operations
O ---- W ---- I ---- TC ---- CD ---- Other ----
2.15 Describe the cutting and shaping methods to be used, and the sequence in which the
operations are to be carried out
O ---- W ---- I ---- TC ---- CD ---- Other ----
2.16 Describe the various types of file that are available, and the cut of files for different
applications
O ---- W ---- I ---- TC ---- CD ---- Other ----
2.17 Describe the importance of ensuring that file handles are secure and free from embedded
foreign bodies or splits
O ---- W ---- I ---- TC ---- CD ---- Other ----
2.18 Explain how to prepare the components for the filing operations (cleaning, de-burring,
marking out)
O ---- W ---- I ---- TC ---- CD ---- Other ----
2.19 Describe the use of vice jaw plates to protect the workpiece from damage
O ---- W ---- I ---- TC ---- CD ---- Other ----
2.20 Explain how to file flat, square and curved surfaces, and how to achieve a smooth surface
finish (such as by draw filing, the use of abrasive cloth, lapping using abrasive pastes)

O ---- W ---- I ---- TC ---- CD ---- Other ----
2.21 Explain how to select saw blades for different materials, and how to set the saw blades for
different operations (such as cutting externally and internally)
O ---- W ---- I ---- TC ---- CD ---- Other ----
2.22 Explain how to cut external threads using hand dies, and the method of fixing and adjusting
the dies to give the correct thread fit
O ---- W ---- I ---- TC ---- CD ---- Other ----
2.23 Explain how to determine the drill size for tapped holes, and the importance of using the
taps in the correct sequence
O ---- W ---- I ---- TC ---- CD ---- Other ----
2.24 Explain how to prepare drilling machines for operations (such as adjustment of table height
and position; mounting and securing drills, reamers, countersink and counterbore tools in
chucks or Morse taper sockets; setting and adjusting spindle speeds; setting and adjusting
guards/safety devices)
O ---- W ---- I ---- TC ---- CD ---- Other ----
2.25 Explain how to mount the workpiece (such as in a machine vice, clamped to table, clamped
to angle brackets); techniques of positioning drills to marking out, use of centre drills and
taking trial cuts and checking accuracy, and how to correct holes which are off centre
O ---- W ---- I ---- TC ---- CD ---- Other ----
2.26 Explain how to produce a sliding or mating fit using filing, scraping and lapping techniques
O ---- W ---- I ---- TC ---- CD ---- Other ----
2.27 Describe the problems that can occur with the hand fitting activities, and how these can be
overcome (such as defects caused by incorrectly ground drills, inappropriate speeds,
damage by workholding devices)

O ---- W ---- I ---- TC ---- CD ---- Other ----
2.28 Explain when to act on their own initiative and when to seek help and advice from others
O ---- W ---- I ---- TC ---- CD ---- Other ----
2.29 Describe the importance of leaving the work area in a safe and clean condition on
completion of the fitting activities (such as removing and storing power leads, isolating
machines, removing and returning drills, cleaning the equipment and removing and
disposing of waste)
O ---- W ---- I ---- TC ---- CD ---- Other ----
NOTE TO ASSESSOR

This unit must be assessed in a work environment and must be assessed in accordance with
the ‘Common Requirements for National Vocational Qualifications (NVQ) in the QCF’ which
can be downloaded from Semta’s website or requested via customerservices@semta.org.uk
Additional assessment requirements have been published by Semta. These additional

assessment requirements are set down in Semta’s unit assessment strategy which can be
downloaded from Semta’s website or requested via customerservices@semta.org.uk
All performance and knowledge requirements must be assessed.
Competent performance must be demonstrated consistently, in line with the

requirements of the unit.
Observation of work activities, examination of work completed and associated records

would be a preferred means of assessing competent performance.
Oral questioning and written answers/tests and practical demonstrations would be the
preferred method of assessing knowledge and understanding. The assessor must have
pre-prepared exemplar answers to written and oral assessments. Assessors must ask
enough questions to be able to determine that the candidate has an appropriate level of
knowledge and understanding as required by the unit. The assessor must retain a
record of the questions asked together with a record of the candidate’s answers.
In order to demonstrate consistent, competent performance for a unit, a minimum of

three different examples of performance evidence must be provided, sufficient to show
that the performance requirements of the unit have been carried out to the prescribed
standards. The minimum number of items specified in each of the scope statements for
a unit (e.g. four from a choice of six) must all be covered, and appropriate evidence
provided. It is possible that some of the scope items may be covered at once. If,
however, the three examples of performance evidence are not sufficient to cover all of
the scope items, then further examples of performance evidence will be required to
ensure this coverage is achieved.
The most effective way of assessing competence, especially for the performance
statements in relation to scope items, is through direct observation of the candidate.
Assessors must make sure that the evidence provided reflects the candidate’s
competence and not just the achievement of a training programme.
Evidence that has been produced from team activities (e.g. maintenance and installation)
is only valid when it clearly relates to a candidate’s specific and individual contribution
to the activity and not to the general outcome(s).
To support holistic assessment items of performance evidence which contain features

that apply to more than one unit, should be used as evidence in any unit where
appropriate.
Performance evidence must be a combination of:

1. products of the candidate’s work, such as items that have been produced or
worked on, and documents produced as part of a work activity, together with a
record of the job reference number or logbook entry against the assessment
criteria.
2. evidence of the way the candidate carried out the activities such as oral and/or
written questioning, witness testimonies, assessor observations or authenticated
candidate reports, records or photographs of the work/activity carried out.
Competent performance is more than just carrying out a series of individual set tasks.
Many of the units contain statements that require the candidate to provide evidence that
proves they are capable of combining the various features and techniques. Where this is
the case, separate fragments of evidence would not provide this combination of features
and techniques and will not, therefore, be acceptable as demonstrating competent
performance.
If there is any doubt as to what constitutes suitable evidence, the external verifier should
be consulted.
TYPES OF MECHANICAL GAUGES

Ruler and scales: They are used to measure lengths and other geometrical parameters. They
can be single steel plate or flexible tape type tool.

Callipers: They are normally of two types- inside and outside calliper. They are used to
measure internal and external size (for e.g. diameter) of an object. It requires external scale to
compare the measured value. Some callipers are provided with measuring scale. Other types
are odd leg and divider calliper.
Venire calliper: It is a precision tool used to measure a small distance with high accuracy. It
has got two different jaws to measure outside and inside dimension of an object. It can be a
scale, dial or digital type venire calliper.
Micrometer: It is a fine precision tool which is used to measure small distances and is more
accurate than the venire calliper. Another type is a large micrometer calliper which is used to
measure large outside diameter or distance.

Feeler gauge: Feelers gauges are a bunch of fine thickened steel strips with marked thickness
which are used to measure gap width or clearance between surface and bearings.
Telescopic feeler gauge: It is also known as tongue gauge and it consists of long feeler gauge
inside a cover with tongue or curved edge. The long feeler strips protrude out of the cover so
that it can be inserted in to remote places where feeler gauge access is not possible.
Poker gauge: This gauge is used to measure propeller stern shaft clearance, also known as
propeller wear down.
Bridge gauge: Bridge gauges are used to measure the amount of wear of Main engine
bearing. Normally the upper bearing keep is removed and clearance is measured with respect
to journal. Feeler gauge can be used to complete the process.

Liner measurement tool: Liner measurement tool is a set of straight assembled rod with
marked length in each set. It is used to measure the wear down or increase in the diameter of
the engine liner.
American Wire Gauge: American wire gauge or AWG is a standard tool which is circular in
shape and has various slots of different diameter in its circumference. It is used to measure
cross section of an electric cable or wire.
Bore Gauge: A tool to accurately measure size of any hole is known as bore gauge, it can be
a scale, dial or digital type instrument.

Depth gauge: A depth gauge is used to measure the depth of a slot, hole or any other surface
of an object. It can be of scale, dial or digital type.
Angle plate or tool: It is a right angle plate or tool used to measure the true right angle of
two objects joined together.
Flat plate: Flat plate is a précised flat surface used to measure flatness of an object when it is
kept over the flat plate.
Dial Gauge: Dial gauge is utilised in different tools as stated above and can be separately
used to measure the trueness of the circular object, jumping of an object etc.
Lead Wire: It is a conventional method to used soft lead wire or lead balls to measure the
wear down or clearance between two mating surfaces. The lead wire or balls of fixed
dimension is kept between two surfaces and both are tightened against each just as in normal

condition. The increase in the width of the lead wire or ball will show the clearance or wear
down.
Snap Gauges:
A snap gage is a form of Go/no go gauge. It is a limit gage with permanently or temporarily
fixed measurement aperture(s) (gaps) which can be adjusted to suit the size of the features
being measured.
A Snap gauge is used in the measurement of external dimensions,

It consist of a U-shaped frame having jaws equipped with suitable gauging surfaces.
A plan gauge has two parallel jaws or anvils which are made to some standard size & cannot
be adjusted
They may be either single-or double –ended

Different types of snap gauge
Thread Pitch Gauges
A thread pitch gauge, also known as a screw pitch gauge or pitch gauge, is used to

measure the pitch or lead of a screw thread. The uppermost gauge in the image is an ISO
metric pitch gauge, the larger gauge in the centre is for measuring the Acme thread form, and
the lower gauge is for Whitworth screws.
Thread pitch gauges are used as a reference tool in determining the pitch of a thread that is on
a screw or in a tapped hole. This tool is not used as a precision measuring instrument. This
device allows the user to determine the profile of the given thread and quickly categorize the
thread by shape and pitch. This device also saves time, in that it removes the need for the user
to measure and calculate the thread pitch of the threaded item.

Profile Gauge
A contour gauge set to the profile of a little pot
A profile gauge or contour gauge is a tool for recording the cross-sectional shape of a

surface.
Contour gauges consist of a set of steel or plastic pins that are set tightly against one another
in a frame which keeps them in the same plane and parallel while allowing them to move
independently, perpendicularly to the frame. When pressed against an object, the pins
conform to the object. The gauge can then be used to draw the profile or to copy it on to
another surface.
Profile gauges are used widely in metalworking and woodworking.

Gauge Block
A gauge block (also known as a slip gauge,) is a precision ground

and lapped length measuring standard. Invented in 1896 by Swedish machinist Carl Edvard
Johansson, they are used as a reference for the calibration of measuring equipment used
in machine shops, such as micrometers, sine bars, calipers, and dial indicators(when used in
an inspection role). Gauge blocks are the main means of length standardization used by
industry.
Ring gauge
A ring gauge, or ring gage, is a cylindrical ring of steel whose inside diameter is finished to
gauge tolerance and is used for checking the external diameter of a cylindrical object.
Ring gauges are used for comparative gauging as well as for checking, calibrating, or setting
of gauges or other standards. Individual ring gauges or ring gauge sets are made to variety of
tolerance grades in metric and English dimensions for master, setting, or working
applications.

There are three main types of ring gauges: go, no go, and master or setting ring gauges.
Go ring gauges provide a precision tool for production comparative gauging based on a fixed
limit. Go gauges consist of a fixed limit gauge with a gauging limit based on the plus or
minus tolerances of the inspected part. No-go or not-go gauges provide a precision tool for
production comparative gauging based on a fixed limit. No-go gauges consist of a fixed limit
gauge with a gauging limit based on the minimum or maximum tolerances of the inspected
part. A no-go ring gauge's dimensions are based on the minimum OD tolerance of the round
bar or part being gauged. The no go ring (OD) gauge should be specified to a plus gauge
makers' tolerance from the minimum part tolerance.
Master and setting ring gauges includes gauge blocks, master or setting discs, and setting
rings are types of master gauges used to calibrate or set micrometers, optical comparators, or
other gauging systems. Working gauges are used in the shop for dimensional inspection and
periodically checked against a master gauge.
Go No/Go gauge
Hardened and ground plug gauge
Replaceable thread and plug gauges

A Go-NoGo gauge (or Go/no go) refers to an inspection tool used to check a work piece
against its allowed tolerances. Its name derives from its use: the gauge has two tests; the
check involves the work piece having to pass one test (Go) and fail the other (No Go).
It is an integral part of the quality process that is used in the manufacturing industry to ensure

interchangeability of parts between processes, or even between different manufacturers.
A Go NoGo gauge is a measuring tool that does not return a size in the conventional sense,
but instead returns a state. The state is either acceptable (the part is within tolerance and may
be used) or it is unacceptable (and must be rejected).
They are well suited for use in the production area of the factory as they require little skill or
interpretation to use effectively and have few, if any, moving parts to be damaged in the often
hostile production environment.

Traceability
In the United Kingdom the National Physical Laboratory (NPL) is the ultimate authority
on units of measurement in the physical sciences.
Manufacturing industry spends many millions of pounds each year making measurements of
all kinds. Such measurements are backed by a hierarchy ofcalibration facilities and services
allowing the calibration of every shop floor instrument to be traced to the appropriate national
primary standard held by the NPL.
This TRACEABILITY is a very important factor in a Company's attempts to maintain and

improve its product quality.
Traceability of Standards in the Calibration of a Micrometer
Hierarchy of standards used in the calibration of a standard micrometer. Each standard used
having its accuracy traced back to the Primary Standard.

The first link in the chain between the shop floor measurement and the NPL is often one of
the laboratories approved to provide a Calibration Service.
These laboratories are entitled to issue calibration certificates with the backing of the NPL
The science of precision measurement is referred to as METROLOGY. A more exact name

for this science would be ENGINEERING DIMENSIONAL METROLOGY, the term
dimensional being introduced as engineers are primarily concerned with the dimensional
features of geometry i.e. length and angle.
Material Standards of Length
The material standards used for length measurement are available in two forms:

 Line comparison standards (rules, tapes, micrometers etc)
 End comparison standards (gauge blocks or 'slip' gauges, length bars)
The summary of characteristics of line and end standards given next indicates that line
standards do not readily provide high accuracy while end standards are more suited to
accuracy requirements of a high order.
End Standards
These consist of sets of standard blocks or bars and are used to build up a required length.
The most common end standards used in industry are Gauge Blocks or Slip Gauges.
These gauges may when they are perfectly clean be slid together with a little pressure adhere
firmly together. This joining together is termed WRINGING’.
Length Bars Slip Gauges
 GRADE 2 (A)
These gauge blocks are intended for shop floor use to set and calibrate fixtures as well
as precision instruments.
 GRADE 1 (AA)

This grade is used within an inspection area to verify the accuracy of plug and gap
gauges as well as setting electronic measuring devices.
 GRADE 0 (AAA)
These higher accuracy gauges are intended for use within a controlled environment by
skilled inspection staff. Mainly used as reference standards for setting high precision
inspection equipment and for the calibration of lower grade gauge blocks.
 GRADE 'K'
Gauges of this accuracy are intended for use within a temperature controlled inspection
room or calibration laboratory. They should be used as masters against which other
gauge blocks are calibrated by comparison.
Reference to a calibration certificate is indispensable in this case.
Accuracy obtainable by various instruments.
Instrument Accuracy (mm) +/-

Caliper set to rule 0.25
Vernire Height Gauge 0.025
Vernier Caliper 0.025
Micrometer 0.01
Micrometer set to Gauge Block 0.005
Gauge Block 0.000015

Mechanical Comparator 0.0025
Pneumatic Comparator 0.0025
Electronic Comparator 0.0015
Co-ordinate Measuring M/c (CMM) 0.0005
Mechanical Dividing Head 2.5 minutes
Optical Dividing Head 20 seconds
Vernier Protractor 5 minutes
Sine Bar or Centres 5 seconds
Combination Angle Gauges 1.5 seconds
The basic unit is the right angle, defined as the angle between two straight lines which
intersect so as to make the adjacent angles equal.
0
 1 right angle = 90 degrees ( )
 1 degree = 60 minutes (‘)
 1 minute = 60 seconds (“)
The Micrometer

Parts of the micrometer:
1. Frame
2. Fixed anvil
3. Spindle
4. Locking lever
5. Sleeve
6. Thimble
7. Ratchet.
Micrometer readings

Reading
Reading
Reading
Reading
Reading
Care and correct use of precision measuring equipment.

1. Select the micrometer that best suits your requirement. Ensure that the type, measuring
range, graduation and other relevant specifications of the micrometer are appropriate for your
application.
2. Always use the ratchet or friction thimble in the appropriate manner, never rotate the
micrometer thimble violently.
3. Avoid parallax errors by reading the micrometer and vernier scales directly from the front
and square on.
4. Do not apply excessive force to the micrometer thimble. Should you be unfortunate and
drop a micrometer, do not use until the micrometer has been re-calibrated/repaired by an
appropriate repair agent.
5. Clean the micrometer after use with a lint free paper or cloth.
6. Always ensure that both the micrometer and workpiece have stabilised to ambient
temperature before measurements are taken.
7. Adjust the zero line in the ambient temperature that the micrometer is going to be used,
remember that a micrometer should be calibrated at 20 deg.C, it may be used in varying
ambient temperatures.
8. Should you mount a micrometer in a stand, ensure that the micrometer frame is clamped at
the centre, do not clamp it too tightly and in any case carry out a zero check in the clamped
position. If in doubt consult an appropriate authority.
9. When storing micrometers for long periods of time, or when they need oiling, use a lint
free paper or cloth dampened with a rust preventative oil and lightly wipe each section,
ensure that the oil is spread evenly over the surfaces.
10. Always leave the measuring faces separated and when not in use, always place
micrometer in its case.
11. Never leave or store the micrometer for long periods of time in a high humidity
environment.
12. Never use a micrometer that has not been calibrated, if in doubt consult an appropriate
authority.

Activity 1. Reading Micrometers. Listed below are a number of micrometer readings, study
each photograph and state the micrometer reading in ‘mm’s
Micrometer reading.
_______
Micrometer reading.
_______
Micrometer reading.
_______
Micrometer reading.
_______
Micrometer reading.
_______
Micrometer reading.
_______
Micrometer reading.
_______
The purpose of drilling

Candidate Name: Candidate Signature:
Date:
Assessor Name: Assessor Signature:
Date:
IV Name: IV Signature:
Date:

Job # 1 Bracket (F1)
Feedback for Bracket Student Name/Date___________________
Bracket ACCEPT REJECT REASON TO SOLUTION
REJECT PROCESS
COMMENTS
Selection of correct material
Correct marking out technique used
Correct use of hand tools
All linear dimensions used within

tolerance
All countersink holes produced

correctly
All holes correct dimension
Job is free of burrs and sharp edges
No visible signs of secondary

operations
Surface finish at all surfaces
Job is identified as students own

work

Drawing Bracket (F1)

Job #2 Handle (F2)
Feedback for Handle Student Name/Date___________________
Handle ACCEPT REJECT REASON TO SOLUTION
REJECT PROCESS
COMMENTS

tolerance
All angular dimensions used within

tolerance

operations

work
Drawing Handle (F2)

Job #3 Allen Screw (F3)

Feedback for Allen Screw Student Name/Date___________________
Allen Screw ACCEPT REJECT REASON TO SOLUTION
REJECT PROCESS
COMMENTS

tolerance
All angular dimensions used within

tolerance

operations

work
Drawing Allen Screw (F3)

Operation Schedule – Bracket F1
Please complete the detailed operation sequence of how you completed the above test piece,
mark as Non applicable were nessessary
Op Details of Operation Details of Tools and Equipment

No.
1 Check bend on 20 x 6 mm bar for 90°
2 Size 45 x 29 mm
3 10 mm square x 30 and 4 Ø3 mm holes
4 Ø5 mm hole x 19 mm
5 10 mm radii
6 Drilled and reamed hole A
7 10 mm radii x 45 mm
Finished Inspection Report – Bracket F1

Please fill in the Finished Inspection Report upon completion of the above test piece
All dimensional tolerances have to be within =/- 0.010” unless otherwise stated mark as Non
applicable were necessary
Op Details of Operation Candidate measurements within or
No. out of tolerance
1 Check bend on 20 x 6 mm bar for 90°
2 Size 45 x 29 mm
3 10 mm square x 30 and 4 Ø3 mm holes
4 Ø5 mm hole x 19 mm
5 10 mm radii
6 Drilled and reamed hole A
Time allowed: 3 Hrs Time Taken: Hrs
Total number of attempts 1-3 , 3-6 , 6 or more
I confirm that the above test piece was manufactured by me and

have inspected thereof to be within the required tolerances and specification.
Candidate Signature:

3. List of Sources – Bracket F1
Please compile a list of the relevant sources of information you have used to complete the
above test piece.
4. Safety Precautions – Bracket F1

Please compile a list of the typical safety procedures and precautions (including
housekeeping,) that you observed during completion of the above test piece.
Date:
Date:
Date:

1. Operation Schedule –Handle F2
Please complete the detailed operation sequence of how you completed the above test piece
mark as Non applicable were necessary

1 Length 120 mm
2 Squared end
3 M6 hole drilled Ø5.2 mm
4 Hole alignment 16 mm – hole A to M6
tapped hole
5 4 x Ø45
6 5 mm radii
7 M6 x 0.75 thread
8 Reamed hole A
9 M6 screw and Ø5 mm hole are in line
2. Finished Inspection Report – Handle F2


1 Length 120 mm
2 Squared end
3 M6 hole drilled Ø5.2 mm
4 Hole alignment 16 mm – hole A to M6
tapped hole
5 4 x Ø45
6 5 mm radii
7 M6 x 0.75 thread
8 Reamed hole A
9 M6 screw and Ø5 mm hole are in line


3. List of Sources – Handle F2
above test piece.
4. Safety Precautions – Handle F2

Date:
Date:
Date:
1 Operation Schedule – Allen Screw F3

Please complete the detailed operation sequence of how you completed the above test piece
mark as Non applicable were necessary
Op Details of Operation Details of Tools and Equipment

No.
1 Assembled parts including supplied M6
screw
2 Parts burr free, un-damaged and clean
2 Finished Inspection Report – Allen Screw F3


1 Assembled parts including supplied M6
screw
2 Parts burr free, un-damaged and clean

Candidate Signature:
3 List of Sources – Allen Screw F3

above test piece.
4 Safety Precautions – Allen Screw F3

Date:
Date:
Date:
1. Describe the Health and Safety requirements and safe working practices and procedures required
for the hand fitting activities undertaken.
………………………………………………………………………………………………
………………………………………………………………………………………………

………………………………………………………………………………………………
………………………………………………………………………………………………
2. Describe the importance of wearing appropriate protective clothing and equipment, and of keeping
the work area safe and tidy.
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
3. Describe the hazards associated with the hand fitting techniques, (such as use of power tools,
trailing leads or hoses, damaged or badly maintained tools and equipment, using files with damaged
or poor fitting handles), and how they can be minimized.
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
4. Describe the procedure for obtaining the required drawings, job instructions and other related
specifications.
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
5. Explain how to use and extract information from engineering drawings and related specifications in
relation to work undertaken.
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
6. Explain how to interpret first and third angle drawings, imperial and metric systems of
measurement, work piece reference points and systems of tolerances.
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
7. Explain how to prepare the materials in readiness for the marking out activities, in order to enhance
clarity, accuracy and safety.
………………………………………………………………………………………………
………………………………………………………………………………………………

………………………………………………………………………………………………
………………………………………………………………………………………………
8. Explain how to select and establish a suitable datum; the importance of ensuring that marking out
is undertaken from the selected datum and the possible effects of working from a different datum.
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
9. Describe the methods of holding and supporting the work piece during the marking out activities
and equipment that can be used.
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
10. Describe the use of marking out conventions when marking out the work piece.
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
11. Describe the ways of laying out the marking out of shapes or patterns to maximize the use of
material.
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
12. Describe the need for clear dimensional accuracy in marking out to specification and drawing
requirements.
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
13. Explain how to set and adjust tools.

………………………………………………………………………………………………
………………………………………………………………………………………………

………………………………………………………………………………………………
………………………………………………………………………………………………
14. Describe the importance of using tools only for the purpose intended, the care that is required
when using the equipment and tools and the proper way of storing tools and equipment between
operations.
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
15. Describe a couple of cutting and shaping methods used while completing the activities and the
sequence in which they were carried out.
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
16. Describe the various types of files that are available and the cut of files for different operations.
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
17. Describe the importance of ensuring that file handles are secure and free from embedded foreign
bodies or splits.
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
18. Explain how to prepare the components for the filing operations.
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
19. Describe the use of vice jaw plates to protect the work piece from damage.
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
20. Explain how to file flat, square and curved surfaces and how to achieve a smooth surface finish.
………………………………………………………………………………………………
………………………………………………………………………………………………

………………………………………………………………………………………………
………………………………………………………………………………………………
21. Explain how to select saw blades for different materials and how to set the saw blades for different
operations.
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
22. Explain how you cut external threads using hand dies and the method of fixing and adjusting the
dies to give the correct thread fit.
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
23. Explain how to determine the drill size for tapped holes and the importance of using the taps in the
correct sequence.
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
24. Explain how to prepare a drilling machine in preparation for using it to perform an operation.
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
25. Explain how you mount the work piece when drilling and how you position the drills to the marking
out, use of centre drills and taking trial cuts and checking accuracy.
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
26. Explain how you would produce a sliding or mating fit using filing, scraping and lapping
techniques.
………………………………………………………………………………………………
………………………………………………………………………………………………

………………………………………………………………………………………………
………………………………………………………………………………………………
27. Describe problems that can occur with the hand fitting activities and how these can be overcome.
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
28. Explain an occasion when you acted on your own initiative and when you had to seek help and
advice from others.
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
29. Describe the importance of leaving the work area in a safe and clean condition on completion of
the fitting activities.
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
Date:
Date:
Date:

2.05 Bench Fitting To Support 206 BM

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CONTENTS FOR LEVEL 2 BENCH FITTING MSFI

Unit No 2.05: Producing components using hand fitting techniques pg 2-14

Types of mechanical gauges pg 15-29

Reading a micrometer pg 30-34

The purpose of drilling pg 35 -43

Bracket Job # 1 Freedback and Drawing pg 44-45

Handle Job # 2 Feedback and Drawing pg 46-47

Allen ScrewJob # 3 Feedback and Drawing pg 48-49

Bracket Operation schedule Inspection,Sources Precations pg 50-52

Handle Operation schedule Inspection,Sources Precations pg 53-55

Bracket Operation schedule Inspection,Sources Precations pg 56-58

Unit Questions pg 59-63

2.05 Issue 1 Dec 2018 Page 1 of 61

Unit Reference Number: J/504/6349 Unit Credit Value: 14 Unit GLH: 64

2.05 Issue 1 Dec 2018 Page 2 of 61

Unit specific additional assessment requirements:

2.05 Issue 1 Dec 2018 Page 3 of 61

2.05 Issue 1 Dec 2018 Page 4 of 61

1.03 Plan the fitting activities before they start them

1.04 Obtain the appropriate tools and equipment for the

1.05 Mark out the components for the required

1.06 Mark out a range of material forms, to include two

1.07 Use marking out methods and techniques, to

1.08 Use a range of marking out equipment, to include

2.05 Issue 1 Dec 2018 Page 5 of 61

1.09 Mark out workpieces which include all of the

1.10 Cut and shape the materials to the required

1.11 Cut and shape two different types of material from

1.12 Use both of the following hand fitting activities:

1.13 Produce components which combine different

2.05 Issue 1 Dec 2018 Page 6 of 61

1.14 Measure and check that all dimensional and

1.15 Use all of the following measuring equipment

1.16 Carry out the necessary checks for accuracy, to

1.17 Produce components to all of the following

2.05 Issue 1 Dec 2018 Page 7 of 61

1.18 Deal promptly and effectively with problems within

1.19 Leave the work area in a safe and tidy condition on

2.0 Know how to produce components using hand fitting techniques

2.05 Issue 1 Dec 2018 Page 8 of 61

I – Inferred response (use only during observation)

Other – Any other agreed assessment method

O ---- W ---- I ---- TC ---- CD ---- Other ----

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O ---- W ---- I ---- TC ---- CD ---- Other ----

O ---- W ---- I ---- TC ---- CD ---- Other ----

2.05 Issue 1 Dec 2018 Page 9 of 61

O ---- W ---- I ---- TC ---- CD ---- Other ----

O ---- W ---- I ---- TC ---- CD ---- Other ----

O ---- W ---- I ---- TC ---- CD ---- Other ----

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O ---- W ---- I ---- TC ---- CD ---- Other ----

O ---- W ---- I ---- TC ---- CD ---- Other ----

2.05 Issue 1 Dec 2018 Page 10 of 61

O ---- W ---- I ---- TC ---- CD ---- Other ----

O ---- W ---- I ---- TC ---- CD ---- Other ----

O ---- W ---- I ---- TC ---- CD ---- Other ----

O ---- W ---- I ---- TC ---- CD ---- Other ----

O ---- W ---- I ---- TC ---- CD ---- Other ----

O ---- W ---- I ---- TC ---- CD ---- Other ----

O ---- W ---- I ---- TC ---- CD ---- Other ----

2.05 Issue 1 Dec 2018 Page 11 of 61