HSC MAJOR PROJECT

By Nicholas Fouskas

2010

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CONTENTS

Statement of Intent page 2/4 Research page 5 Development of Concepts & Idea page 6 Selection & Justification of Materials, Components,

Processes & Other Resources page 7/10 Finance Plan page 11 Problems page 12 Timeline page 13/23 Student Evaluation page 24

Statement of Intent: I intend to design and contruct a Revolving Parts Bin in a octagon shape

for my HSC major work. It consist of a Lazy Susan bearing to spin the 32 compartments for the

components. This project will be called MPB which is acronym for “Multi Parts Bin”, as

it can be used in a variety of objects. This allows get more than 20 compartments in just over a square foot of

work bench space, and can still have a quick and easier access to everything available in a Lazy Susan, which lets the user to spin the bin to get the parts needed.

Motivation & Purpose of the Project:

This project is being developed to produce a Multi Parts Bin and this is an innovative design to solve people’s problem and keeping it nice and tidy.

It will be an easier transportable job for when a user can take it to any place at she or he wants.

It will consist of all requirements for a Multi Parts Bin (MPB), with room for all small parts, and has some small compartments for the parts as well.

I would like to create a piece of furniture with medium quality of workmanship, and having the skill to design this awesome project.

If it proves to be a marketable product; it will be aimed at general population.

The labels for the compartments can be used to identify the names for the small parts and even the overall, MPB is very effective for the practical storage and it makes the project to look good.

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Parameters of the design:

Have a new modern appearance Allow all sized components to fit comfortably Strong, sturdy and stable 360 degrees (full turn spin) Look attractive to people who use it Be less than $1000.00 in total cost Have a smooth wood grain finish, which will make it aesthetically

pleasing to the eye and to the touch.

What are the possibilities?

The components placed neatly in each of the compartments and the compartments labels will show how neat the project is and they also will be made from good finished BB Hoop Pine to match a good style project.

This will be in a shape of an octagon for each level of compartment and the reason for this shape is because there is room for the small and medium sizes components, which displays the tidiness of the job. They will be made from a 3/4” thick plywood frame that serves as a “backbone” that runs all the way through the parts bin.

Then the BB Hoop Pine: bottom pieces are added to establish the individual compartments and to keep the contents from spilling out. The thin BB Hoop Pine strips are attached to each compartment at the front.

The triangular compartments on the corners introduce some additional angles and the parts bin rotates on a Lazy Susan bearing. This bearing lets the user put the bin close to a wall and still have access to everything in it.

The repeated steps of making an octagon shape have resulted in some imperfections. Slight twists can be seen on the second level of the finished product.

There are four separate tiers (with eight compartments each) that help to organize small parts and pieces of hardware and three different sizes of compartment to hold pieces of various sizes. Each compartment has a base where it is fitted with grooves on the side of the support barrier, so heavy objects can’t break through the base of each compartment.

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Research: I borrowed books from the school library for ideas, e.g. “Wood Smith

Custom Woodworking” by the editors of Wood Smith magazine. It also had other projects in it and provided ideas on how they

constructed a project. I discovered that a rotating parts bin maximises the use of space for

placing components in each of the compartments. I have visited three timber places: “Bunning’s Warehouse” and at

“Randwick Boys’ High School” and “RALLIS TIMBER”. To get the idea of my project I researched several pictures from this

websites:- http://www.vestilmfg.com/products/mhequip/storage-PBIN.asp - http://www.cisco-eagle.com/catalog/c-676-44-diameter.aspx - http://www.amazon.com/Diameter-Rotabin-Rotating-Parts-Cabinet/

dp/B000Z51W6G- http://progressivefarmer.com/farmer/store/projects/rotatingbin.html - http://books.google.com.au/books?

id=Jd8DAAAAMBAJ&pg=PA138&lpg=PA138&dq=rotating+parts+bin+from+wood&source=bl&ots=AsJEryzRNZ&sig=2pI8W47akPmO0Z9WdZYmxgczcZI&hl=en&ei=nHzzSvX-FZP06gP7rJAI&sa=X&oi=book_result&ct=result&resnum=9&ved=0CB4Q6AEwCA#v=onepage&q=rotating%20parts%20bin%20from%20wood&f=false

- http://www.rd.com/images/tfhimport/2002/Sep02_Garage_Storage/ 20020901_Garage_Storage_page002img001.jpg

- http://www.globalindustrial.com/p/storage/bins-totes-containers/ rotating/34-diameter-rotabin-rotating-parts-bin-cabinet-2

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Development of Concepts & Ideas:A key concept was to ensure comfort for the user of the bin, by enabling him or her not to slouch over too much.

Another concept was to ensure a maximum height for the storage of components in each compartment.

Most of my size requirements came from the book “Wood Smith Custom Woodworking” by the editors of Wood Smith magazine.

Most people are able to remove the components and place them in different compartments easily.

The height allows for users to adjust the rotation of the spin, however, for transportation, the unit is most effectively moved when empty.

Multi Parts Bin shows how to get 32 compartments and still has a quick and easy access to everything in it.

This project is good for areas such as: schools, industrial arts workshops, home workshops, hardware stores and anywhere where an ordered collection of small parts is required.

Lazy Susan will be polished professionally to give a shiny gold colour and keeping it clean at the end of the completion of the project.

The Veneer strips provide the completion of the project with patterns, which the Lazy Susan must match with the pattern.

To maximize clarity and longevity of labels, I placed a plastic cover over each label of each compartment section of the unit.

Although the project is not perfect, it looks good and it’s extremely functional.

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Selection & Justification of Materials, Components, Processes & Other Resources:

Materials:

The wood chosen is BB Hoop pine, Australian Timber, and very easy to work with. It has a clear, even grain on it and is strong. The timber is not rough and it is the best timber to use for this kind of project.

From the research my design will include the following:

Side Panel (2) because it is needed to support the project together and to create an octagonal shape.

Center Divider (1) because it consists of two pieces, which is halved into two sections from the one shape.

Wings (4) because it brings the sides together to make the shape of an octagon and the compartments as well.

Ctr. Btm. Pieces (8), Side Btm. Pieces (8), Crnr. Btm. Pcs. (16) because it is the base of each compartments.

Lg. Fcng. Strips (16), Sh. Fcng. Strips (16) because it uses a very important technique to make the shape of an octagon.

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Components:

Rh Sheets- Metal Screws (4)

- Metal (timber use), easy to obtain, simple to attach, strong, less chance of mistakes, provides smooth screwing and unscrewing.

Fh woodscrews (8)

- Metal (for wood), easy to obtain, simple to attach, economical, strong and comfortable for the use of BB Hoop Pine.

Wire brads (42)

- Brass (timber use), easy to use, quick to nail it in, easy to attach into the timber.

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Lazy Susan (1)

- Metal (rotation), easy to use, quick to access to any compartments, looks attractive, and strong.

Long label holders w/tacks (32)

- Labels (display the names for each compartment), easy to assemble and good looking and even easier to find the compartment that the user is looking for.

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Processes & Other Related Resources:

Edging (strips for finishers)

- Great finishers, it makes the job perfect and neat, effectively masking corners and the edges of the timber There is also a range of different colours.

Attaching Base:

- (Dowels), to put the Lazy Susan into place.

- (Screws), to hold the base together

- (Grooves), for the slots of the compartments

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Project Finance Plan:

No. Item Expected Cost

Actual cost Date of purchase

Budget/ Balance

INITIAL PURSE $1,000

2 BB Hoop Pine (Timber) $145.00 $200.00 25/01/2010 $200.00

32 Long Label Holders $60.00 $45.00 1/02/2010 $45.00

4 Metal screws $15.95 $20.00 4/02/2010 $20

8 Wood screws $21.95 $25.00 4/02/2010 $25.00

42 Wire brads $32.50 $10.00 5/02/2010 $10.00

1 Glue (PVA) $12.25 $5.00 12/02/2010 $5.00

2 Printing ink colour $160.00 $140 12/0/2010 $140.00

2 Iron on edging timber (veneer) 5m

$30.00 $19.60 7/04/2010 $19.60

1 Spray Paint (Polyurethane)

$45.00 $35.76 9/04/2010 $35.76

1 Stain Interior Proofint (Jarrah) 250ml

$20.00 $18.43 8/04/2010 $18.43

TOTAL $518.79

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Problems:

I used 19.05mm of BB Hoop Pine Timber, instead of 12.7mm which was used on the bases. This increased the weight of the final unit. The base for each compartment should be hard board as it is a lighter colour, but I used the same timber of 3.175mm BB Hoop Pine Timber. In my initial calculation of timber required, I provided for too much. There are enough pieces left to do two projects of the same style, so I used it for backup in case something went wrong.

School periods lengths presented a problem for extended periods of work. The time indicated for measuring and cutting and putting it together is too short 50 minutes to continue with the project, 5 minutes to clean up, and all up is 55 minutes lessons a day except Tuesdays and Wednesdays which 40 minutes a lesson a day, so I take sometime of during my free period and work on my project.

12.7 mm BB Hoop pine has a problem with the involvement in the support barrier where the base as limited space and didn’t go through the 3.175 mm groove depth. To resolve this problem I did something which was pretty smart to do of hiding the grooves and glue access. But sometimes were able to see a cap between the slots and the open grooves again, so I did the same thing to make a bit smaller.

To create good finishes to the project, I sanded the rough area of the surface of each piece of the facing strips and the support barrier as well; but there were caps on the corners, so I put a bit of patching up (dressing it up) and then continuing sand it afterwards. The book that I got the project from was in the measurement of inches, which I converted it to millimetres instead.

The dark colour stain that I put made the pudding orange, because I think that I put too much of it on the job, but still it looks alright with the different colour textures. But clearing the timber up at the end was a nightmare because there were a lot of dirt and pencil marks on it and some of Veneer strips are chipped off.

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Project Timeline:

Day One: 8/2/10 – 9/2/10

Bought the timbers Measuring the first sheet Using a square and long ruler, pencil and rubber ¾ of BB Hoop Pine (2.400mm x 1.200mm) Measuring on the long side of the sheet 5 mm gap between each sections

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Day Two: 9/2/10 – 10/2/10

Continuing measuring Double checking to find errors

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Day Three: 16/2/10 – 18/2/10

Marking the grooves for each pieces first Cutting the each pieces out after done the grooves Using a Circular Saw to do the grooves and cutting out the pieces (on

teachers allowed to use the Circular Saw not students). Also cutting the round base for the Lazy Susan

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Day Four: 22/2/10 –23/2/10

Finished cutting the pieces out Getting ready to put the support barrier together first

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Day Five: 1/3/10 – 5/3/10

Putting the support barrier without gluing or nailing Gluing the first part of the support barrier Making sure that it is a perfect 90o angle

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Day Six: 8/3/10 – 10/3/10

Continuing gluing the first part together and after start on the 2nd part First part complete and moving onto the 2nd part, which is the same

thing as the first part. Making sure that is a perfect angle of exactly 90o

Clamp each side by using a G clamp Gluing the two parts together and nailing each part together

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Day Seven: 15/3/10 – 17/3/10

Measuring the slots of the bases The slots for the bases been cut from using a Jigsaw Organizing the lengths of the bases

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Day Eight: 18/3/10 – 22/3/10

Sanding the timber down to remove all of the pencil marks first Making a nice smooth finishes and keeping the job clearing before the

assembling the facing strips

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Day Nine: 23/3/10 – 6/4/10

Starting to put the slots in to reform a base for each compartment’s Each slots is in a 90o angle Using a band saw to cut the slots out Starting to put the facing strips Clap it after been nailed and glue in Cutting out the angles for the corner pieces Continuing the steps 4 times (4 levels)

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Day Ten: 8/4/10 – 14/4/10

Finished putting the facing trips Starting to sand for finishers and puncher the nails in and covering with

a little bit of pudding. Putting on the veneer edging strips by using an iron and carefully cut the

size out using a scissor. Jarrah stains afterwards underneath the job not on the top and in each

compartment to match the lazy Susan colour texture by using a small paint brush and an old cloth and then spraying the Polyurethane coat onto the job.

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Day Eleven: 20/4/10 – 12/5/10

Putting on the Lazy Susan onto the project underneath the base. Polishing the Lazy Susan into a gold colour shine Placing a bearing onto a plate for rotation Screwing the brozer colour screws into the the Lazy Susan and into the

timber aswell. Making a lazy Susan out of Steel and Bronze The full completion of the MPB project The plate been grooved down a bit

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Student Evaluation:

I am happy with the finished design, because it was my best project that I made in my life so far.

I should start cleaning the timber before assembling it together, because at the end; cleaning was a nightmare to remove the pencil marks and the dirt on the timber, but now I know what it’s like to keep it at the last minute after completed the project and making sure next time keep the groove square, so that the slots fit perfectly and clean.

The Multiple Parts Bin the name of my chosen design demonstrates how an easy storage compartment can access less than a few seconds.

However the problems that I counted for the first time was pretty difficult to get around it to a solution that took me days to figure it out, which some of them was easy to make a mistake twice.

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But without the support of teachers and friends and family; I couldn’t complete the project.

This design did answer my Statement of Intent, which tells everything for the ongoing planning and the final result of the completion of the project.

The Lazy Susan was the most difficult thing to get, because I have design rough sketch with approximate measurements to fit with the base of the project.

But it was hard to make it, so I draw up the design first and then gave the measurements and the drawings to my dad to cutting and do the grooving to form a plate for the Lazy Susan.

I did pretty well with my finance plans because I knew what sort of things were cheap and expensive, but it didn’t or get close to the limit of 1000 dollars.

The timeline was working very well, because I’ve spread my free time working on the project and didn’t waste any time on it from the start to the finish.