The Folding Shovel

The Shovel is a fantastic, relatively quick project for junior and senior metal workers. This particular shovel unfolds to 3 feet and folds up to 1 foot.

Materials 5/8” diameter pipe 8”1” diameter pipe 8” 1” diameter bar 1 1/4” 5/8” diameter bar 2”1/2” NC Bolt 2”1” angle iron 2”1/4” rod 1”18 gauge steel sheet 8 3/4” X 6 7/16”1/2” NC Threaded rod 1 1/2”

ToolsSheet metal shear Box and pan break MIG Welder Hack saw Drill pressHammer Metal lathe Pedestal grinder Sharp center punch ½” TapAviation shears File

Shovel Blade Procedure

1. Cut out a copy of the shovel sheet metal layout found at the back of this package.

2. Use a school glue stick to glue the paper cut out to a piece of sheet metal make sure not to be wasteful, make sure the edges of the paper line up with the edges of the metal.

3. Cut along the 2 parallel edges of the paper using the sheet metal shear. Make sure that the cuts are square.

4. Place the Sheet metal in the shear so the angle at the end of the shovel lines up with the blade. Cut both angled sides.

5. Use a pair of aviation snips and cut out the profile at the top of the shovel.

6. Clamp the Shovel blade in a vise and file the edges smooth.

7. Place the shovel blade in the box and pan break and line up one of the hems with the fingers on the break. Fold the hem over as far as possible.

8. Slide the folded edge

under the fingers of the box and pan break close the fingers to bend over the hem. Remove the paper and try to keep it in one piece.

9. Once both hems are folded over with the box and pan break hammer them flat.

10. Re-glue the paper to the opposite side of the the shovel blade so that it lines up.

11. Place the shovel blade in the box and pan break so that the fingers of the break line up with the broken line on the paper pattern.

12. Slightly bend the side of the shovel blade up. A very minimal bend is important. Repeat with the other side of the shovel blade

13. Using the same method as the first set of the hems, fold the hems at the end of the shovel blade. If they do not bend past 90 degrees a hammer will have to be used to get the full bend. Before bending the hems all the way over, remove the paper.

14. Place one of the 2 tabs under the finger of the

box and pan break and bend it up 90 degrees. Repeat with the other tab. The shovel blade is now finished.

Hinge Side Procedure

1. Cut 2 pieces of 1” angle iron 1” long, make sure that the edges are square.

2. Mark a line 1/2” in from one edge of the angle iron. Cut very carefully along the line.

3. On the long side of the angle iron measure down ½” and in ½” and center punch.

4. Mount the angle iron on the drill press and drill through on the center mark with a ¼” bit. Repeat steps 2-4 on the other piece of angle iron. The hinge sides are now finished.

Swivel Joint Procedure

1. Cut the head off of the ½” NC bolt.

2. Measure and center punch a mark ¼” from the cut surface of the bolt. Bolts are normally hardened steel, so make sure you use a good punch.

3. Clamp the bolt in the drill vise so that it is dead square to the drill bit. Drill trough with a ¼” bit.

4. Bevel the cut end of the bolt on the pedestal grinder. This part is now finished.

Shovel Blade Assembly Procedure

1. Cut a piece of ¼” rod 1” long

2. Assemble the two hinge sides with the ¼” pin and the swivel joint.

3. Set the part up on the welding table so that the 2 pieces of angle iron are equal, and there is a small gap (1/32) between each side of the angle iron and the swivel. Once they are equal weld around the outside of the ¼” rod. On both sides.

4. Set the hinge assembly on the end of the shovel blade, so that it is centered and flush with the top. Spot weld the hinge to the shovel. Spot welds are used so that the shovel blade is not warped.

The shovel blade assembly is now finished.

Large & Small Pipe Procedure

1. Cut 2 pieces of pipe, one 5/8” diameter and the other 1” diameter, both to a length of 8”. The thickness is not crucial, but keep in mind that thicker equals stronger and thiner equals lighter. The two pieces of pipe must also slide with in each other

2. Face off both sides of the pipes on the lathe. If time permits and you have a knowledge of boring on a lathe this is a good time to bore 1” in to the pipe to remove the weld. It is not necessary, but it does help produce a straighter handle. The pipes are now finished and ready for assembly.

Small & Large Pipe Ends Procedure

1. Using a hack saw cut two pieces of solid 5/8” rod 1 1/16” long and one piece of solid 1” rod down to 1 5/16”.

2. using the metal lathe face off both sides of each piece. Bring the 5/8” pieces down to a total length of 1” and bring the 1” piece down to a total length of 1 1/4”.

3. Place one of the 5/8” pieces back in the lathe. Start turning down the diameter of of the part. Only cut ½” along the part. Continue decreasing the diameter until the end fits inside the end of the small pipe. The tighter the fit, the stronger the shovel. Repeat with the other piece of 5/8” rod.

4. Place the 1” rod in the chuck. Using the same method as step 3, turn the diameter of the end so that it fits in side of the 1” pipe. Make sure only the first ½” is turned down.

5. A slight chamfer can now be cut on the wide thick end of all three parts. This can be down free hand or by adjusting the compound rest.

6. On the lathe center drill one side of all 3 pieces. Then drill with a 29/64” drill (the tap drill for a 1/2” - nc thread)

7. Obtain a ½” - NC tap that has a centering mark on the end (small hole). Place the beginning of the tap in the hole drilled in step 5. Place the tap stock on the end of the tap and finally bring the live center forward so the tip is resting in the centering hole. Do not apply to much pressure. Apply some thread cutting oil to the tap. Keep light pressure on the tail stock and at the same turn the tap stock in 2 turns to start the thread. Once the thread has been started, turn the tap stock a ½ turn forward at the same time turn the tail stock hand wheel to maintain light pressure. Loose in the the tail stock hand wheel and turn the tap stock ¼ turn back to break the bur coming of the thread. Apply tail stock pressure again and make another ½ turn forward. Release the tail stock and break the bur. Continue this process until the tap is ½” in to the stock. Once there back off the tail stock and continue the ½ turn forward, ¼ turn back technique until the tap goes all the way through the part easily. Repeat the process with the other two pieces.

Handle Assembly Procedure

1. Cut a piece of ½” -NC threaded rod 1 ½” long.

2. Thread the threaded rod in to one of the 5/8” pipe-ends so that ½” is protruding from the top.

3. Bring the part to the welding area and use the MIG welder to weld around the bottom . Holding the rod securely to the pipe-end.

4. Place the new welded pipe end inside of the 5/8” pipe and tack weld it in. When doing this maximum penetration is important so make sure the MIG welder is set for thick steel. Also hold the tip in place slightly longer to ensure good penetration.

5. Weld the other 5/8” end-cap in to the other end of the pipe. Using the same method weld the 1” end-cap in to the 1” pipe.

6. Clamp the pipe in the lathe so that 2” of the end are protruding from the chuck.

7. Using very small cuts turn the welds on the pipe down so that they are level with the pipe surface. Do not take to much off. Repeat for the other end of the 5/8 pipe and for the 1” pipe.

Finishing

There should now be three components, the shovel blade and the 2 handle parts. Screw the end of the small handle to the swivel joint tightly and screw the large handle to the end of the small handle. To fold it up, slide the large handle over the small handle and turn it to screw it on and then loosen the swivel joint turn it so that the shovel blade is against the handle. Tighten the small pipe to lock the shovel in position.

Take the shovel back apart and paint it the colour of your choice.

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