CMT Portfolio James Miles

AS 91057
1.20
6 credits
Implement basic procedures using resistant
materials to make a specified product

Introduction
This year in year 11 mechanics the class has been asked to make a unit to solve the
issue of lack of storage. We have been given 8 weeks of class time to complete a
CMT portfoleo and a further 15 weeks to make the unit our stakeholders have
chosen (in my case a trolley). We choose our stakeholder and then the stakeholder
decides on what we make and everything about what we make, e.g the physical and
functional attributes. We will need to plan our time wisely when doing the paperwork
and making our project due to our time being limited.

Special features
 Safety Edges
I will incorporate safety edges on the trolleys trays to ensure no sharp edges on the
trays of the trolley which could pose a danger to the user of the trolley or anyone in
contact with the trolley, The safety edge will also ad structure to the trolley trays
which is another positive of safety edges. The trays are going to be made out of mild
sheet steel and having a safety edge will strengthen the trolley as well as take away
any chance of cutting somebody's hand or it getting caught on clothing. A safety
edge on the trolley will involve bending the sheet steel of the trolley over on itself to
give the tray a new edge. This will give the edge a slightly more rounded finish due
to the bend as shown in the diagram below. A safety edge will be added to all of the
edges of all three trays of the trolley.

 MIG Welding
I will be using MIG welder to fuse all of the permanent joinings of the trolley. MIG,
also known as GMAW (Gas Metal Arc Welding) is a process in which an electric arc
is formed between an electric conductor and a metal surface. This heats the metal to
a temperature hot enough to cause it to melt. When this process is done between
two metal surfaces it causes them to melt together forming a strong, permanent
bond between them. The school workshop welder is set up as follows: amperage -
16.6, wire speed - 4.5 metres per minute, argoshield - 20 litres per minute. The
settings are required for 1.6 mm thick steel. (the sheet steel on the trolley is 1.5mm
which is adequate for the MIG welder settings. A butt and fillet weld will be used on

the trolley.

Describe the overall appearance

Finish of the trolley: - This trolley will have three trays, each tray will need smooth
edges to prevent any cuts or scratches. The way this will be completed is by
smoothing out any sharp edges with a file. Safety edges will be incorporated on the
walls of the trolleys trays. A result of not smoothing all the edges of the trolley could
be getting clothes caught on sharp edges damaging the stakeholders clothing. The
trolleys environment is going to be inside the workshop at home where it is very easy
to accidentally brush up against it and get caught on any sharp edges. This is why I
will make sure to remove sharp edges from the trolley to avoid any injury to a person
or any objects on or beside the trolley.
Paint: - I will paint the trolley with dark hammerite green paint, so a smooth finish on
the trolley will help when it comes to painting the frame because if it has smooth
edges, the trolley will have a nicer finish after being painted. Painting the trolley will
help prevent the trolley from rusting so the trolley will last longer when painted as
well. The main reason for dad choosing the colour of dark hammerite green is
because other equipment in the workshop is also this colour and the trolley will fit
better into its environment.
The trolleys aesthetic design: - The trolleys aesthetic design will be made to look
tidy and simple, To my stakeholder it is more important that the design be very
strong however the trolley will be made to look nice after the priorities for the trolley
are met. The trays in the trolley: - The middle main tray will be on slides to allow for
easy access to this tray in the trolley. Even though the middle tray will have the
ability to slide out on rails, There will be no chance of the shelf falling out of the
trolley due to a stop in the rail which does not allow the shelf to move any further
than ⅔ of the way out. Even though The middle tray will be on slides, it will still be
very strong and sturdy.
Size: - Size is a very important factor in this project because the trolley cannot be too
big where it is hard to move around the workshop, but it can't be too small because
the trolley will be not as good at storing large items. The size of the trolley will be
able to fit through the smallest gap around the workshop at home because at this
size the trolley could easily be moved around the workshop but it also gives the
stakeholder the maximum amount of storage space within the trolley.
Appearance: - The trolley will have a minimalistic finish. It will be painted in dark
hammerite green because Dad has other equipment in the workshop which is this
colour e.g the Lathes, Pullmax, jigs etc. If the trolley is this colour it will look like it
belongs in the shed. The welds will be smooth to avoid cuts and the smooth welds
will look nice aesthetically. When the trolley is not in use it can be kept in its set
storage space where it will blend in and not look out of place in the workshop.

  
Gantt Chart
Job 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Order materials that I need for

the trolley

Measure the mild steel sheet

and angle iron ready for cutting
to size

Cut metal to size

Mark sheet steel for bending

Bend sheet metal into the trays

of the trolley

Weld the draining tube into the

top tray
 Get angle iron and trays in place
for welding

Welding

Grinding

Coat finished trolley with dark

hammerite green paint

Make sure finished product fits

specifications of all stakeholders
of the trolley

Specifications
The outer dimensions of the trolley: 1,006mm length x 606mm width x 940mm high
Top tray (1st tray) dimensions: 1000mm length X 600mm width
middle tray (2nd tray) dimensions: 880mm length X 600mm width
Bottom tray (3rd tray) dimensions:  1000mm length X 600mm width

Main materials for trolley

50 X 50 X 3 angle iron
X4 lengths at 828 mm
X2 lengths at 600mm
1.5mm Sheet steel 1420mm X 820mm
X4 112mm high X 115mm long X 80mm wide Trolley wheels ($66.77 for all four)
25mm diameter steel pipe 40mm long
Dark hammerite green paint (all of trolley except the slides and wheels will be
painted)
MIG wire (will be used in the welding done on the trolley)
600mm X 10mm X 10mm slides

Material
The material the trolley will be made out of is mild steel. Some properties of mild
steel include being: Tough, ductile, malleable, good tensile strength, conductive,
poor resistance to corrosion etc. It has a melting point at 1600 degrees celsius. Mild
steel is a general purpose engineering material and also can be seen in many
everyday objects such as metal tables, shelves chairs etc. Mild steel is an adequate
material for the trolley as it’s properties such as its strength and toughness will
exceed the requirements of the trolley when the mild steel is used in the
configuration of the trolley.

Techniques applied to conform with

health and safety
Health and safety regulations were applied at every stage of producing the trolley to
ensure safety when making the trolley. For example, when using the grinder and the
plasma cutter, safety glasses and an apron were worn to protect against sparks from
the eyes and body. Safety was the number one priority throughout the construction
of the trolley.     

Objective Testing
I will perform thorough tests on the trolley itself and on the same types of materials
used on the trolley (being mild steel angle iron, mild steel sheet, Mild steel slides and
mild steel trolley wheels ). I will do this to ensure the trolley is safe as well as reliable
when constructed out of these materials. The trolley will be used regularly which
means that it is very important that it is more than capable to handle all stresses that
the trolley has been designed to handle. From my dads and teachers experience, I
have learnt that 25mm by 25mm angle iron when used in the design and
configuration of the trolley I will be more than adequate to withstand larger weights
than 150 kg (the maximum weight the trolley will have to take). And the 1.5mm sheet
steel when used in the trolley will also be adequate. However I can not rely on advice
and so tests will still done on the materials to be used trolley to ensure the materials I
use will be safe when used in the trolley, and the characteristics of the materials are
adiquiet when used on the trolley. The tests I will perform will include: Weld test,
bend test, impact test, cut test, drill test, heat test and scratch test.

Weld test
The objective of this test is to ensure MIG welding will permanently join the material
of the trolley together with an adequate amount of strength. I will do a weld test
between the same mild steel materials to be used on the trolley. I will do this to
ensure the welds on the trolley will be strong and durable enough to withstand the
maximum weight of 150kg when this material is in the configuration of the trolley.
The welds on the trolley will be permanent which means it is important that the welds
on the trolley are done to a high standard and bond well with the mild are done to a
high standard and bond well with the mild steel of the trolley.

Flexibility test
The objective of this test is to ensure the mild steel materials used on the trolley will
not bend under an inadequate amount of pressure. I will do a bend test on the same
sheet metal and angle iron I will be using on the trolley. This is to ensure the
materials I will be using on the trolley are strong enough to ensure the materials will
not bend under the weight the trolley is designed to hold.

Impact test
The objective of this test is to ensure the mild steel material will not fatigue or break
under sudden impacts. An impact test will be done on my angle iron and sheet steel
to ensure that the sheet and angle iron materials will not break under sudden
impacts. This material must withstand being hit several times with a hammer with no
fractures or breaks within the material for this material to be suitable for the trolley.

Cut test
The objective of this test is to ensure the mild steel material will not easily cut and
will not be damaged when in the workshop. I will perform a cut test on the angle iron
I plan to use on the trolley. I will do this to the the cutting resistance of the materia is
adequate for the trolley and the material will not cut when easily when the trolley is
complete.
Drill test
A drill test will be done on the materials used on the trolley to ensure that the
material can stay structurally strong even with structural damage added to it such as
a hole in the material. A drill test will also be done to add damage to the angle iron
and sheet steel and then the strength will again be measured to make sure these
materials are still adequate for the trolley even with damage

Heat test
I will perform a heat test to ensure the materials used on the trolley will be able to
withstand a suitable amount of heat. The angle iron and the sheet steel will be
heated up using a oxy acetylene torch until the material is unsuitable due to it being
too malleable from the heat. If this temperature is below 100 degrees celsius then
the material is not suitable however i do not think there will be any problem with this
as mild steels melting point is 1600 degrees celsius and the trolley will never be
subjected to this heat.
Scratch test
I will perform a scratch test on the on the materials used on the trolley to ensure it
will not scratch when accidentally exposed to sharp objects. If the material scratches
too easily it is likely to be easily damaged when exposed to a workshop environment
when it occasionally rubs up against other objects. I will apply different forces of
pressure with a scribe on mild steel  and if the material scratches too easily it will
likely also be susceptible to getting scratched in the workshop

(Sign Offs on objective tests)

Type of Photographic Teacher and/or Teacher and/or Teacher Teacher
test evidence of Stakeholder Stakeholder and/or and/or
testings verification that the verification Stakeholder Stakeholder
being applied test has been that the test verification verification
performed with has been that the that  the
accuracy. performed health and tests were
independently. safety done in a
guidelines manner that
have been economises
applied time, effort
accordingly. and
materials.
 Weld test above

Flexibility above
test

Impact above
test

Cut test above

Drill test above

Heat test above

Scratch above
test.     

Subjective Testing
I will perform subjective tests on the trolley to ensure the trolley will be aesthetically
pleasing in the opinion of the stakeholders of the trolley and anyone else who
happens to come into contact with the trolley. This is important for the the trolley due
to the aesthetics of the trolley being apart of my stakeholders requirements. Tests
will be done on the fell of the trolley aswell to ensure no sharp edges of rough
surfaces.

Aesthetics test
Tests will be done on the same type of mild steel which will be used on the trolley.
This test will be done to ensure the paint holds well to the mild steel and is
aesthetically pleasing to look at. The mild steel might also affect the shade of the
dark hammerite green so this test will also be done to make sure the shade of the
colour is not changed too significantly. The paint should add a smooth surface to the
mild steel when applied on the trolley, as well as this, the paint must have a strong
bond on the material and must not chip easily. The paint will also be tested on the
welds on the trolley due to the welds on the trolley being painted along with the
majority of the rest of the trolley. The paint will also add protection against rust to the
trolley which will result in a longer lasting trolley that does not rust. The colour (dark
hammerite green) of the paint when used on the mild steel of the trolley must also
have a similar shade to other equipment in my stakeholders shed to ensure the
trolley fits in with the trolleys  environment aesthetically as well as functionally.

Smell test
The Smell of the trolley will be tested by making sure the trolley does not release any
strong, unwanted smell. I do not think the smell of the trolley will cause any issues
due to the mild steel and paint (when dry) not causing any strong smell. My
stakeholder does not want the trolley to be odorless. The smell test will be completed
by smelling the mild steel and dry paint to be used on the trolley. If there is no strong
smell it is adequate for the trolley.

Touch / texture test

The trolley must feel smooth to touch to ensure nobody in contact with the trolley
gets cut or scratched when handling the trolley. The trolley must also be smooth to
ensure it does not catch on anything when being moved around the workshop. The
way this will be tested is by running my hand across all surfaces of the trolley. If I feel
any unwanted rough or sharp edges or surfaces, I will have to address these issues
for the trolley to be adequate and acceptable for the stakeholder of the trolley.

(Sign Offs on Subjective tests)

Type of test Photographi Teacher and/or Teacher Teacher Teacher
c evidence Stakeholder and/or and/or and/or
of tests verification that Stakeholder Stakeholde Stakeholde
being the test has been verification r r
applied performed with that the test verification verification
accuracy. has been that the that  the
performed health and tests were
independentl safety done in a
y. guidelines manner
have been that
applied economise
accordingly s time,
. effort and
materials.

Aesthetics above
test

Smell test above

Texture test above

Techniques
I will use many techniques when constructing the trolley which will include using
different tools and skills in order to complete the trolley to a higher standard
compared to what I could have without these techniques. I will be using a plasma
cutter, angle grinder, bender, MIG welder, grinder and other various tools at different
stages when constructing the trolley, as well as the techniques I used when sourcing
materials for the trolley.
Purchasing and Acquiring the material for the trolley
My primary stakeholder of the trolley has decided he would like to obtain all of the
materials for the trolley separately from the school instead of getting the materials
through the school. This could allow for the materials to be bought cheaper than it
would through the school due to dad having personal contacts with people who could
possibly get the steel cheaper than what the school could. Dad bought the metal
from steel and tube.

Scribing and measuring on the material

I will use a scribe to outline my measurements on the material for the trolley. This
technique will be used because a scribe line will leave an easily seen line on where
to cut, bend, weld on the material etc.

Plasma cutting
I will cut out the trays used on the trolley using  a plasma cutter.A plasma cutter will
make a clean and square cut on the sheet steel meaning no sanding or finishing will

need to be done after the sheet steel has been cut.

Angle Grinding
In order to cut the angle iron to size for the trolleys frame I will use an angle grinder. I
chose to use this tool as it will provide an acurite cut to the mild steel and will be
adequate in accuracy for the trolley.  
Bending
I will bend the sheet steel on the trolley trays because this will add structure to the
trolley trays as well as provide a lip on the tray to prevent liquid, small objects etc fall
out of the trolley trays. A bended tray will be a much cleaner and tidier tray

Hammering
In order to fully bend over the safety edges on the trolley I will have to use a hammer
to hit the edge completely over and flatten the edge down. In order to protect the
mild steel from dents I will use a piece of scrap wood against the steel and hit the
wood to bend over the metal. This will distribute the impact across the wood and
therefore distribute the impact across the mild steel. This will result in no dents on
the material because the impact is over a large area.
English wheel
I will use an english wheel to fully bend the safety edges on the trays over fully and
to make sure the bend is compact with not an overly round edge. The english wheel
will take out any dents made from the hammer if there are any and will leave a

smooth and sharp bend on the safety edges.

MIG Welding
I will use MIG welding to permanently join majority of the joining of the trolley. MIG
welding will make for a strong, durable and permanent join on the trolley. It is the
most adequate technique for the trolley due to dad (my primary stakeholder) wanting

a strong permanent join.

Grinding
In order to have smooth welds and edges on the trolley I will use a grinder to grind
down the welds to a smooth finish and I will also use the grinder to smooth any other

sharp edges.  
Drilling
In order to plug weld the mild steel legs of the trolley to the trolley trays, specific
holes must be cut in the material to create a hole for plug welding. Holes will also
have to be drilled in the middle tray to allow for a place to screw the slides onto the
tray.

Tapping
In order for the screws to screw into the middle tray to hold the tray to the slides,
holes will be cut and tapped so the crews can tightly hold the middle tray to the
slides this tray moves on. Even though these screws are securely holding the trolley
on their own, the screws will also be welded in place for an even stronger,
permanent bond holding the middle tray to the slides of the trolley.

 
Painting
In order to resist corrosion on the trolley as well as make the trolley aesthetically
pleasing, I will paint the trolley with dark hammerite green paint. This will be done
using a spray gun to get and even coating of paint on the trolley.   

(Sign Off on Techniques)

Type of Photographic Teacher and/or Teacher Teacher Teacher
test evidence of Stakeholder and/or and/or and/or
 techniques verification that the Stakeholder Stakeholder Stakeholder
being applied technique  has verification verification verification
been performed that the that the that  the
with accuracy. technique has health and techniques
been safety were done
performed guidelines in a manner
independently. have been that
applied economises
accordingly. time, effort
and
materials.

Purchasing above
and
Acquiring
the
material for
the trolley

Scribing above
and
measuring
on the
material

Plasma above
cutting

Angle above
Grinding

Bending above

Hammering above

MIG above
Welding

Grinding above

Painting above
(photos of the trolley before painting)
 CMT Portfolio
AS 91057
6 credits
1.20
     Implement basic procedures using resistant
materials to make a specific product

BEN SHARP

Introduction
This year in year 11 we have been assigned to make a piece of storage to fix a
storage issue in our house, I am going to be making a gun safe for my stakeholder
who is my dad. We have been asked to complete our design portfolio on designing
our piece of storage. In this portfolio I will be making a gantt chart and will be doing a
step by step way of how I made the safe and all of the techniques and features that
were involved in the making of this safe. This year my teacher has introduced us into
3 standards, the first standard is brief development and the context is storage, I am
to find a stakeholder from home to help me design my storage( a gun safe). Other
people called wider stakeholders will also be involved in the design.
Special Features
Mig welding
I will be using mig welding because it is perfect for what I need. I will be using mig
welds because these welds are accurate and will get the job done well and will be
strong, looks nice and will be very practical. The sochool workshop welder is set up
as follows, amperage 16.5, wire speed 4.5 meters per minute, argoshield is coming
out at 20 litres per minute, these are all of the setting required for 1.6mm mild steel.

Press Break
I will be using this press to bend my sheet metal into the shape of a gun safe. I will
be using it because it has the power to bend and shape 3mm mild steel. It will make
a good job and do the job with ease.

Describe Overall appearance

This year in year 11 metal work we have to design and build a unique piece of
storage for a chosen stakeholder. My stakeholder is my Dad and he has chosen the
storage to be a gun safe. The reason that he would like me to build a safe is
because our existing safe is rapidly running out of room. The safe that I will be
building is going to be. 2m x 0.650m x 0.250m. With one door on the front and a
separately lockable ammo safe at the top. The safe will be painted matte black and
will be flush on the ground.  My dad would like a deadbolt lock style on the door and
have steel pin hinges. Add mild steel, mig weld all of my joints. The reason that I will
be building this gun safe is because of the fact that my stakeholder wants it, my
stakeholder would like this gun safe because of the fact that he is running out of
room to store all of his guns and all of the ammo that we buy. This gun safe will solve
my stakeholders problem by creating a unique piece of storage.
Doors: The gun safe will have to have doors that won't be too big and will allow
easy access into the safe, these doors will have a strong feel and will be able to lock
the guns up very safely. The gun safe will have to meet all of the requirements of our
local laws and regulations. The local laws say that
Size for storage: This gun safe will have to be reasonably big, it will have to be
bis so that I can fit all of my guns into the safe. I will have to account for the storage
for ammo, I will have to make a separate door or a couple of draws at the bottom so I
will be able to store all of our ammo, for a safe set up.
Strong frame: This safes structure and frame will have to be very sturdy, it will
have to be sturdy because of the fact that the sheer weight of the guns and ammo
that will be going in it. A slab of ammo is 10kg each gun would be about 6kg, and we
always have about two slabs at a time in the safe, and about ten guns on top of that.
Safe and meets laws: In our area the gun safes have to meet certain
regulations, the safes walls will have to be a certain thickness and have to be bolted
to the ground, the ammo has to be seperate from the guns and the ammo and guns
have to be locked up.
Smooth: The metal will have to have a nice and smooth finish, the welds will also
have to have a smooth and tidy finish so the appearance looks good.
Looks: This safe will have to have a nice look and design to it because everything
in our garage is well built and it will need to look tidy and well built or it will look out of
place.
Colour of paint: The colour that I will be painting it will be either black or grey
because I don't want a colour that will stand out to much, the safe can't be a bright
colour because it will look out of place in the garage because everything else in the
shed is a dull colour.
Size: The size of this safe will have to be reasonably big because of how much
ammo and how many guns we have.

Being safe and using correct ppe equipment while

building safe
Welding: Have to wear welding mask to protect eyes, gloves to stop burning, aprin
to stop clothes igniting.

Grinding: Safety glasses to prevent sparks going in eyes, an aspirin if not wearing
suitable clothes and gloves to stop burns.

Guillotine: Need to watch out for fingers and sharp edges on the metal. Make sure
before you cut everybody is clear.
Press Brake: Gloves for handling the metal when moving it around to prevent
cutting, hands well clear of the hydraulics and moving parts to prevent loss of fingers
or crushing.

General PPE in workshop: In the workshop there will always be people using
power tools and will be heavy objects around the place. So in the workshop it would
be in your best interest to wear the following: steel cap boots, safety glasses,
overalls to protect from sparks and just be aware of your surroundings to keep you
and the people around you safe.

Gantt chart
WEEK 1 2 3 4 5 6 7 8 9 10 11 1 13 15 16
2
JOB
Acquire metal

Measure out
back and two
sides of metal
on one sheet
of steel

Guillotine back
and two sides
of metal on
one sheet

Fold back and

two sides of
metal on one
sheet

Measure out
the bottom and
top plate for
the safe

Guillotine the
rough size of
plate

Grind out the

exact shape of
plates to fit the
safe

Measure tabs
on the front of
top and
bottom plate

Bend the tabs

on the plates

Measure out
the shelf, with
a bent up tab
at front

Cut out shelf

Bend front tab

on shelf

Measure out
the door

Cut out door

Bend tabs all
around door

Weld the top

and bottom
plate onto the
safe

Grind off exes

welds on safe

Weld in shelf

Weld hinges
on safe and
onto the door

Measure shelf
door

Cut shelf door

out

Weld on shelf
hinges

Paint the safe

and inside an
industrial grey
Specifications
The size of my safe is going to be
Height- 2m
Front Width- 0.650m
Side width (depth)- 0.250m
Specs
Mig welding for connecting my joints
Steel pin hinges for the doors
Mild steel for the whole safe
Deadbolt lock on door
Flanges for the easy joining
Box section along the top of the door for strength
Press brake for bending my metal
 Testing (objective) metal
Testing that I am Photographic Dad and Dad and Dad and
going to use evidence of Chris Chris Chris
during the testings being verification verification verification
manufacture applied that the that the tests that health
process technique economizes and safety
has been time, effort guidelines
performed and materials have been
with applied
accuracy accordingly

Weld Test C. ANDERSON J.SHARP. J.SHARP

J.SHARP C.ANDERSON C.ANDERSON
I welded two bits
of steel together
and then hit the
weld, one thing
that I found was
that the weld was
very very strong
and wouldn't
budge.

Bending Test C. ANDERSON J.SHARP. J.SHARP

J.SHARP C.ANDERSON C.ANDERSON
I stood on top of a
cut out of steel
and put it between
two benches and
it bent a little bit
but when i stood
off it bent back
into place and left
no impact or
bend.

Impact Test C. ANDERSON J.SHARP. J.SHARP

J.SHARP C.ANDERSON C.ANDERSON
I the same bit of
steel that I bend
tested and got a
big workshop
hammer and hit
the plate over and
over, it left no
indent or marks.
Cutting Test C. ANDERSON J.SHARP. J.SHARP
J.SHARP C.ANDERSON C.ANDERSON
I used the bench
cutter to cut some
3mm mild steel
plate to see how it
would stand up
against it but the
cutter went
through it quite
easily.

Drilling Test C. ANDERSON J.SHARP. J.SHARP

J.SHARP C.ANDERSON C.ANDERSON
I did some drilling
on the metal that I
welded and it took
a lot for a hand
drill to get through
the steel.

Heat Test C. ANDERSON J.SHARP. J.SHARP.

J.SHARP C.ANDERSON C.ANDERSON
I got a furnace
and an
oxyacetylene
torch and heated
up some steel.
The furnace made
the steel red hot
and made it easy
for the hammer to
shape it, the torch
slowly melted the
steel and made it
red hot.

Techniques
Techniques Photographic Dad and Dad and Dad and
that I am evidence of Chris Chris Chris
going to use techniques being verification verification verification
during the applied that the that the that health
manufacture technique techniques and safety
process has been economizes guidelines
performed time, effort have been
with and materials applied
accuracy accordingly
Acquire metal C. ANDERSON J.SHARP. J.SHARP
I purchased my J.SHARP C.ANDERSON C.ANDERSON
metal of steel
and tube 2
sheets of mild
steel for gun
safe.

Measure out C. ANDERSON J.SHARP. J.SHARP

back and two J.SHARP C.ANDERSON C.ANDERSON
sides of metal
on one sheet
of steel
Ready for
guillotining the
base of the safe
with a square
and felt pen.

Fold back and C. ANDERSON J.SHARP. J.SHARP

two sides of J.SHARP C.ANDERSON C.ANDERSON
metal on one
sheet
To get the most
out of one sheet
with the
hydraulic press
break.

Measure out C. ANDERSON J.SHARP. J.SHARP

the bottom J.SHARP C.ANDERSON C.ANDERSON
and top plate
for the safe
Ready for
cutting.
Measured with
tape measure
and square.

Guillotine the C. ANDERSON J.SHARP. J.SHARP

rough size of J.SHARP C.ANDERSON C.ANDERSON
plate
Cut plate with
two tabs being
required to be
cut out with
hand grinder.

Grind out the C. ANDERSON J.SHARP. J.SHARP

exact shape of J.SHARP C.ANDERSON C.ANDERSON
plates to fit the
safe
Grind off the
tabs ready for
putting onto the
safe.

Measure tabs C. ANDERSON J.SHARP. J.SHARP

on the front of J.SHARP C.ANDERSON C.ANDERSON
top and
bottom plate
To get ready to
bend with
measured lines
to go off.

Bend the tabs C. ANDERSON J.SHARP. J.SHARP

on the plates J.SHARP C.ANDERSON C.ANDERSON
Ready to be
welded onto the
safe.

Measure out C. ANDERSON J.SHARP. J.SHARP

the shelf, with J.SHARP C.ANDERSON C.ANDERSON
a bent up tab
at front
For the shelf
with a tab to
make a nice fit.

Cut out shelf C. ANDERSON J.SHARP. J.SHARP

With the J.SHARP C.ANDERSON C.ANDERSON
guillotine ready
to be bent.

Bend front tab C. ANDERSON J.SHARP. J.SHARP

on shelf J.SHARP C.ANDERSON C.ANDERSON
To stop cutting
oneself and to
make a nice
surface for the
lock.
Measure out C. ANDERSON J.SHARP. J.SHARP
the door J.SHARP C.ANDERSON C.ANDERSON
With a tab all
around it ready
to be cut and
then bent.

Cut door C. ANDERSON J.SHARP. J.SHARP

With the J.SHARP C.ANDERSON C.ANDERSON
guillotine and
prep for the
press.

Bend tabs all C. ANDERSON J.SHARP. J.SHARP

around door J.SHARP C.ANDERSON C.ANDERSON
With the press
and ready for
putting on the
safe.

Weld the top C. ANDERSON J.SHARP. J.SHARP

and bottom J.SHARP C.ANDERSON C.ANDERSON
plate onto the
safe
With a mig
welder and get
ready for
grinding.

Grind off exes C. ANDERSON J.SHARP. J.SHARP

welds on safe J.SHARP C.ANDERSON C.ANDERSON
I did this with a
grinder starting
off with a meaty
wheel moving
my way to a
sanding wheel,
to make a
smooth surface
ready for
painting.
Weld in shelf C. ANDERSON J.SHARP. J.SHARP
I mig welded in J.SHARP C.ANDERSON C.ANDERSON
the shelf for a
strong neat
secure shelf.

Weld hinges C. ANDERSON J.SHARP. J.SHARP

on safe and J.SHARP C.ANDERSON C.ANDERSON
onto the door
I mig welded on
the hinges very
accurately for a
nice moving
door with a
strong feel and
hard to break
into.

Measure shelf C. ANDERSON J.SHARP. J.SHARP

door J.SHARP C.ANDERSON C.ANDERSON
With a square
and a pen
ready to
guillotine.

Cut shelf door C. ANDERSON J.SHARP. J.SHARP

out J.SHARP C.ANDERSON C.ANDERSON
With the
guillotine to
make a clean
accurate cut
and fit.

Weld on shelf C. ANDERSON J.SHARP. J.SHARP

hinges J.SHARP C.ANDERSON C.ANDERSON
From a shop in
Christchurch,
two hinges on
shelf.
 C. ANDERSON J.SHARP. J.SHARP
J.SHARP C.ANDERSON C.ANDERSON
Paint the safe
and inside an
industrial grey
To get a nice
finish on the
safe with a
compressed air
booth. A
professional set
up.

Subjective Testing
Subjective Photographic Stakeholde Stakeholder Stakeholde
testing that I evidence of r verification that the r
am going to subjective verification subjective testing verification
use during testing being that the economizes time, effort that health
the applied subjective and materials and safety
manufactur testing has guidelines
e process been have been
performed applied
with accordingly
accuracy
Aesthetics J.SHARP J.SHARP J.SHARP
Test
The safe
looks great, it
is tall and
finished well.

Smell Test J.SHARP J.SHARP J.SHARP

The safe
smells as
expected,
like paint but
very weak.
Touch/feel J.SHARP J.SHARP J.SHARP
Test
The safe
feels smooth
and no rough
bits from
weld.

Stakeholder Subjective Testing

Subjective Photographic Stakeholder Stakeholder Stakeholder
testing that I evidence of verification verification verification
am going to subjective that the that the that health
use during the testing being subjective subjective and safety
manufacture applied testing has testing guidelines
process been economizes have been
performed time, effort applied
with accuracy and materials accordingly
Aesthetics test J.SHARP J.SHARP J.SHARP
The safe came
up good and he
has done a
good job.

Smell test J.SHARP J.SHARP J.SHARP

The safe just
smells like dry
fresh paint.

Touch/feel test J.SHARP J.SHARP J.SHARP

The safe is
smooth and
feels strong.
 Conclusion
Throughout the process of building my gun safe with feedback from my stakeholder I
have learnt many new techniques with using the tools and equipment and have
improved existing knowledge. From the brief design of the product to the end product
there has been many variations thrown into the mix and I believe that I have got the
most out of my opportunity to solve an issue for storage whitch in my case was a
lack of storage for guns. If I were to do this project again here are the things I would
do different. First of all I would try and get more work done in the first while of the
time given, this would allow more planning and more time at the other end to get it
finished and done to my best ability, I still have achieved my project and I am very
proud of how it has come out.

BEN SHARP
2018
YEAR 11