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HOW TO MAKE HARDWAREwork for you

T O O L G u I D E

obey your genesHere’s a scenario that should resonate with practically every one of our DIY-oriented readers, especially those to whom weekends represent a glorious opportunity to Do Stuff That Needs to Be Done. To be honest, this is more akin to a genetically programmed imperative than an optional leisure-time activity: although you may not be aware of it, every cell in your body is urging you to grab a tool and fix things or make stuff.

Now let’s consider the (very few) readers who have yet to make the leap of faith to DIY nirvana. We’ll assume you’re in a quandary: whereas you neither understand nor care about tools and what they can do, you have been instructed by your partner to “fix that shower today or forget about conjugal rights for the next 20 years”.

What to do?In both cases, your best bet is to make a list of the

tools and materials required for the job, then visit your favourite hardware store and ask someone for advice. Personal experience suggests that you will promptly ignore this advice and spend the next two hours wandering among the shelves, examining all manner of interesting (and occasionally inexplicable) items, and end up buying far more stuff than you need to complete your project.

There is absolutely nothing wrong with this. Although the shower job is unlikely to require an angle grinder or a set of quality German spanners, these tools will undoubt-edly come in handy at some point in the future. Do not falter. If your purchases meet with grim disapproval at home, point out that you are merely asserting your constitutional right to bear tools (hey, it’s not as if we’re advocating easy access to AK-47s).

As always, our annual Tool Guide provides you with some excellent tool-buying ideas – and here we are also addressing the partners of DIY mavens. If there’s a birthday coming, or you simply want to do a favour for someone special, this is where you’ll find the solution.

There’s more: we test your tool knowledge with a fun quiz, introduce a trio who tell us about their favourite tools, show you how to build a stylish pot-rack from scrap, and take you inside a factory that turns out some of the best-quality tools on the planet.

Now go out there and fix something.

The Editors

ConTenTs3 Letter from the Editors

4 My favourite tool

6 Test your DIY IQ

14 Priced to go: under R100 gifts

15 Okay, I can still afford R500

17 Hey, R1 000 won’t kill me

18 All-in-one solutions

20 Fit for the job

23 Build a scrapyard pot rack

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DIy sound man GRAnT IMMELMAn Industrial ventilation specialistand hardcore audiophile.

Favourite tool: Soldering iron

Immelman derives immense satisfaction from building high-quality sound components that he couldn’t otherwise afford. Forever taking his hi-fi apart and adding modifications that he’s researched online, he’s currently building his own Gainclone amplifier. “I wouldn’t be able to build my own high-end ampli-fiers without my trusty soldering iron,” explains Immelman.

M y fAV o u r I T E T O O L

Motor headPETER PALM CAR magazine’s road test engineer.

Favourite tool: teleScopic inSpection mirror

Not all indispensable tools have outrageous price tags. A humble telescopic inspection mirror might cost less than R40, but without it, Palm would never be able to check for leaking pipes or broken hoses. “Many components under the bonnet are impos-sible to see from above, or from underneath for that matter!” explains Palm. “I can angle this tool from above, illuminate the area with a torch and always see what’s going on.” l

Mr Fix ItTOM FAIR Retired high school maths teacher, now general handyman.

Favourite tool: cordleSS drill

After downing his chalk and calculator on retirement, Fair soon discovered the convenience of cordless power when he started his general handyman business. When undertaking jobs that require drilling holes, driving screws and coun-tersinking, he can have as many as three cordless drills on the go at once, but his favourite by far is a Makita 18 V lithium-ion drill driver. “The Li-Ion battery pack is great. If the battery goes flat while I’m on site, a quick 10- to 20-minute charge is usually all it requires for me to finish what needs to be done,” says Fair.

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T E S T y o u r D I Y

iQSo, you know how to build, fix or customise anything, huh? We’ll see about that.

Valedictorian. Straight A student. Magna cum laude. After graduation, those acco-lades don’t mean much if you can’t answer the central question of adulthood: Can you fix that thing?

Of course you can. You read PoPular Mechanics. So this quiz – an objective evaluation of your home and automotive abilities – should be a breeze. You can eyeball a perfect mulch mound from across the yard, you anticipate oil changes like you have an internal odometer, and you can cement PVC pipe in your sleep. Right? Carve a fresh edge into your carpenter’s pencil and let’s find out.

BY HARRY SAwYERSPICTuReS BY JAMeS WoRReLLILLuSTRATIoNS BY SPLITINTooNe

1. You just poured a con crete slab for your new

patio, and you have an itch to wheel out the grill. To get wet concrete to cure properly, you should:– A. Expose it to sunlight– B. Sprinkle it with silica gel– C. Put a fan on it– D. Cover it to keep it moist

2.Six pieces of information appear on a tyre sidewall

label that reads P245/40ZR18. P means “passenger car”, 245 is the width of the tyre (in mm) when mounted, and 18 is the diameter of the rim in inches. Which of the following is not indicated by the 40, Z and R in the middle of the code?– A. Aspect ratio– B. Optimal air pressure– C. Speed rating– D. Construction

3. You’re always on your ladder, either keeping the gutters spick and span or

rescuing local cats trapped in trees. So you know the rung rules: which ladder step is safe to stand on?

– A. Top cap– B. Rear step

– C. Top step– D. Second step

4. Some recent experimentation with fuel-saving gadgets

gave you a pleasing, placebo-charged feeling of success, but the numbers didn’t show any fuel savings at all. Changing your driving behaviour is more likely to get the results you seek. Which of the techniques below will actually improve your fuel economy?– A. Increasing tyre pressure– B. Accelerating more gently– C. Turning off the a/c– D. All of the above

5. After spending a year in the woods building your midlife

crisis cabin with an axe and mallet, you’re ready to return to the world of power tools. Which of the following saws’ blades should not be moving when it makes contact with the material to be cut?– A. Chain saw– B. Circular saw– C. Mitre saw– D. Reciprocating saw

A

B

14. When a local car dealer-

ship liquidated its inventory, you scored a compres-sor almost as big

as an SuV. The 230-litre beast runs at 2,25 kW and blows an average of 10,2 cfm (0,3 m3 per minute or 17 m3 per hour) at 6 bar. Still, it’s limited – which of these tools could it not power? – A. Brad nailer – B. 10 mm impact wrench– C. Orbital sander– D. Finish nailer

15. Cigarette butts that

visiting family ground out on your old oiled pine flooring (how times have changed!)

have left some unsightly blemishes over the years. To patch a damaged sec-tion, you cut out a sooty spot with a plug-cutter, fashion a matching plug to fit it, sand it flush and oil the area. The repair you’ve made is called a:_ A. German repair_ B. Scotsman repair_ C. Dutchman repair _ D. Myanmarman repair

6. You want to insulate the attic, and you’re fairly hip to the latest in

high-tech heat retention. Glass fibre batts have a thermal resistance rating (or R-value) of 3.1 to 4.3 per inch (25,4 mm), and higher R-values mean better efficiency. How do new products compare with the big pink? Identify the insulation with the highest R-value from the list below.– A. Mineral wool– B. Cellulose– C. Polyurethane spray foam– D. Recycled blue jeans

7. The hammer is your primary problem-solving tool – you’re just

that type of craftsman. When hammering machined surfaces or fragile parts, which type of tool is inappropriate to use?– A. Lead hammer– B. Ball-peen hammer– C. Brass hammer – D. Rawhide hammer

8.You’re laying a floor that will be used regularly to host plus-size

stiletto square-dancing nights. You need the hardest wood available – which of these is your material of choice? – A. Maple– B. Cherry– C. Hickory– D. Bamboo

9.You’re pressure-washing the patio with a 40-degree nozzle, moving

the tip side-to-side in a slow sweep about half a metre from the concrete. But stains under the bird feeder aren’t coming up. For more power and a focused beam, which nozzle size do you need?– A. 15-degree nozzle– B. 60-degree nozzle– C. Third-degree nozzle– D. No nozzle; just put your thumb on the hose tip

10.You’re convinced that modern paint chemistry is a conspiracy

– the low-VoC trend, in particular, rouses your suspicions – so you prefer to use a traditional oil-based alkyd whenever pos-sible. Which job is ideal for an oil-based paint, rather than a new latex acrylic?– A. Interior drywall– B. Exterior plaster– C. Exterior ironwork– D. Interior woodwork

11. You spread mulch because you think it’s pretty, but you don’t like to admit that to

your rugby pals. It’s practical, you say – when spread around shrubs, mulch retains moisture, inhibits weed growth and keeps roots from over-heating. To maintain your cred in the scrum, when should you apply mulch, and how much of it?– A. Apply liberally in spring – can’t have too much of a good thing – B. Sprinkle less than 5 cm when the heat hits 30°.– C. Spread 5 to 10 cm over cool, moist soil in springtime – D. Real men don’t mulch

12. The cheapo wheel spanner that the manu- facturer threw in the boot is demonstrating

its shortcomings – it won’t loosen the tyre’s wheel nuts. What’s the best way to get the stuck nuts moving?– A. while holding the spanner steady on a nut, kick the tyre to depressurise the fastener– B. Fit the spanner on a nut, slip a metre-long pipe snugly over the spanner end, and pull the pipe end anticlockwise– C. Turn the spanner clockwise; stuck lug nuts are often reverse-threaded– D. Hold the spanner on a nut while a helper quickly drives the car in reverse

13. The world of abrasives doesn’t start and end with sand- paper. The following tools can reshape surfaces in a hurry –

but only one item has the scour power to take rust off ferrous metal parts. For coarse credit, which is it?– A. Drywall rasp – B. Carbon-steel wire cup brush – C. General-purpose mill file – D. Ceramic and marble file

6 7

D

C

wHAT To Do?16. Your pickup is dead in the driveway and needs a jump. So you hook the red cable

to the positive terminal of the dead car, repeat for the booster, then connect the black cable to the negative terminal of the booster battery. Where should the final black wire’s clamp be connected?– A. Dead battery’s negative terminal– B. Dead vehicle’s engine block

– C. Dead battery’s positive terminal– D. Leave it loose for good luck

18. After shaping the edges of soft, nonferrous metals, the teeth on your single-cut file become clogged with metal shavings, prohibiting a smooth finish. The tool you use

to clear out the file’s teeth and keep it cutting properly is called a:

– A. File card – B. File pick – C. File driver – D. File solution

19. You’ve been putting off the chore long

enough – today’s the day you finally buckle down and build your potato can-non. After cutting the PVC pieces to size and cleaning the ends you plan to join, what’s the next step?– A. Apply primer to the male end and PVC cement on top of that. wait 5 minutes, repeat for the female end, then fit them together – B. Dry-fit the pieces and fire a test potato– C. Brush primer on the inner rim of the female end and the outer rim of the male end. Apply PVC cement on top of the primer. Fit the ends together immediately– D. Apply primer to each end, wipe it off, slather PVC cement to the ends, wipe it off, and then fit each piece together

17. Conversing with the gentlemen at your local back-street drag race, you claim

that your modified BMW’s supercharger is superior to a rival’s Nissan GT-R turbocharger. What’s the difference between a supercharger and a turbo?

– A. There is no difference– B. Superchargers produce more power– C. Exhaust gases drive a turbo; super-chargers run off the crank, like alternators– D. Only superchargers use ultracool air from the climate-control system 2

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2625

27.

20. After years of yanking loose branches from

the yard’s treetops with a frayed extension cord, you’ve learned that you may be using the tool unsafely – especially when it’s also plugged in. Which of the following is an appropriate use of an extension cord? – A. As permanent wiring concealed under floors or behind walls – B. As wire tied to an over-head pipe in the basement workshop – C. As a power source for a toaster, heater, coffeepot or any other electric heating appliance – D. As 230-volt service through a grounded three-prong outlet to power a non-heat-producing appliance

21. How often should you replace your vehicle’s oil?– A. Every 5 000 km– B. Every 8 000 km– C. Every 12 500 km– D. As often as the owner’s manual says

22. Your workshop wouldn’t be complete without this automotive tool, which

can separate the ball joints, tie rods or pitman arms from a suspension upright (aka the knuckle). What is the tool’s name?

– A. Pickle fork– B. Pitman fork– C. Double-tine fork– D. Bi-prong fork

23. If this wall is load-bearing, which way does it run in

relation to the direction of the joists?– A. Perpendicular– B. Parallel– C. Backwards– D. There’s no hard-and-fast rule

24. A pair of red wires dangles from this installed outlet. What

connection is broken?– A. Live wire– B. Neutral wire– C. Ground wire– D. Tripwire

25. When installing a medicine cabinet, you went a little wild

with the Sawzall and cut this pipe. What type of fitting can reconnect it?– A. Bushing– B. Adapter– C. Coupling– D. Flange

26. What is the typical distance on-centre between studs in

drywall?– A. 30 cm– B. 40 cm– C. 60 cm– D. One pace

Your serpentine belt’s looking rough, and any day now you expect to find it lying detached in the driveway. How do you know when it’s time to replace a serpentine belt that’s grown long in the tooth?– A. Replace it when you change your oil– B. Change it when you rotate your tyres– C. Replace it when the surface scales and it begins to fray– D. A decent serpentine belt should last forever

wHAT’S THAT?

8 9

C

29. You and your beloved circular

saw have been through thick and thin... timber. But which material can not be cut using a circular saw fitted with a wood-cutting blade?– A. PVC moulding– B. Oriented-strand board– C. Medium-density fibreboard– D. Fibre-cement sheeting

30. You’re modifying a scrap 50 x 100 to

replace a rotten deck-rail spindle. Cutting the wood with handsaws, you’re tackling its long edge before trimming to length. In the correct order, which two saws do you need?– A. Crosscut saw, ripsaw– B. Hacksaw, ripsaw– C. Ripsaw, chain saw– D. Ripsaw, crosscut saw

32. After struggling to remove a tyre, you

want to make the nuts easier to turn next time. What tool turns lug nuts to the ideal tightness when mounting a tyre?– A. Pneumatic wrench– B. Breaker bar– C. Torque wrench– D. Tyre iron

33. You’re trying to learn the names of

your ramshackle Victorian home’s fancy carvings so you can navigate the millwork catalogue without just tracing the profile and hoping you order the right replica piece. Last time, corbels came instead of crown moulding. Which of the following is not the name of an actual house part?– A. Mullion– B. Tympanum– C. Festoon– D. Nasturtium

wHAT’S THAT?

B

A

D

34. These bits put holes in brick, glass, metal and wood – but only one of these, sized 35 mm in diameter, is the perfect tool to install invisible European Soss-style hinges on cabinet doors.

Which bit is it?

– A. Bimetal hole saw – B. Forstner bit – C. Carbide-tip bit – D. Masonry bit

28. Your old house’s walls are out of square, making this woodworking tool – which can measure, copy and mark any angle – an indispensable gauge. every crafts-

man owns one, but rarely will two identify it by the same name. Whatchamacallit?

– A. Sliding bevel square

– B. T-bevel – C. Adjustable bevel square

– D. All of the above

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31. It’s tough to remove a roll pin that has rusted in place over the years. These pins lock gears and

levers to a shaft such as a clutch cable arm. To get a stubborn one to budge from its position, you should:– A. Use a roll-pin punch nearly as big as the pin – B. Drill it with a high-speed-steel bit the same size as the pin– C. Use a roll-pin punch about half the pin’s diameter– D. Lube it in wD-40 and extract it with a rare-earth magnet

1. D Concrete doesn’t dry – it cures via a chemical reaction between cement and water. The reaction takes place over five to seven days, during which time it’s critical to keep the fresh pour cov-ered and moist. Stake a tarpaulin over the patio and mist the slab once every 24 hours.2. B Air pressure recommendations appear on the driver’s side doorsill or in the owners’ manual, not here. The only pressure number on the tyre is the maximum air pressure – not a recommended level. 3. D Second step down fromthe cap.4. D Increasing the tyre pressure reduces the rolling resistance. Go-ing easy on the accelerator pedal provides an efficient throttle input. And a/c requires engine power to run, reducing fuel economy. 5. D Hacking at an old gutter with a moving reciprocating-saw blade just might knock you off a ladder. Instead, wedge the saw’s blade and shoe firmly against the mate-rial before pulling the trigger. Get the other saws’ blades spinning at full speed before carefully making contact with the workpiece.6. C Polyurethane insulation materials typically have an R-value of about 7,0 to 8,0 per inch, and rigid polyurethane panels with foil facings can get up to 8,7. With an R-value of 3,0 to 3,8, loose-fill cellulose ranks near glass fibre batts. Same goes for shredded blue jeans, with a 3,4 to 3,7 R-value, and for mineral wool, about 3,7. 7. B Ball-peen hammer. The ball-peen – and not your old carpenter’s framing hammer – is appropriate for striking chisels, punches and other hardened metal. use softer faces such as lead or brass for delicate work.8. C Hickory is the hardest here, falling in at 1 820 on the Janka hardness scale. Cherry is at 950, bamboo measures 1 380, and maple scores 1 450.9. A The 15-degree nozzle’s narrow spray can cut caked mud off the lawnmower and strip weak paint from brick. The wider, gentler, 60-degree spray can apply mixtures of cleaning chemicals and water to weathered decks and wood siding.10. C Acrylic paints are superior to alkyds – except on exterior iron-work. Scrape away loose paint and

rust, apply an oil-based primer, and clean with mineral spirits.11. C overdoing mulch actually stresses the plant – pile it 5 to 10 cm high, and avoid burying the plant’s root stem. Apply mulch in cool late spring to give the plant’s roots insulation against the first hot sunshine.12. B The problem with those cheap wheel spanners is that the short handle gives the user little leverage. The pipe extends the handle and increases the user’s mechanical advantage over the nut the wrench is turning.13. B Carbon-steel brushes like this one work on ferrous metals, but can introduce rust and con-tamination to stainless steel.14. C At up to 11,3 cfm at 6 bar, the orbital sander’s continuous draw may overtax this machine during extended periods of use. The compressor can handle the 10 mm impact wrench (2,5 to 3,5 cfm at 6 bar), the framing nailer (2,2 to 5,0 cfm) and brad nailers (0,3 cfm to 1,3 cfm). 15. C Dutchman repairs often stand in contrast to the surround-ing flooring, and on historic floors exposed to years of wear, it’s not uncommon to see several such patches. The aesthetic is so distinct that some engineered flooring manufacturers have built faux Dutchman repairs into the finished product when replicating historic styles.16. B Connect one end of the positive (red) cable to the positive (+) terminal on the battery of the dead car, then repeat for the booster car. Connect one end of the negative (black) cable to the negative (–) terminal on the booster battery. Then connect the other end

of the negative (black) cable to a clean, unpainted metal surface (such as the engine block) on the engine of the disabled vehicle. 17. C Both the turbo- and super-charger are pumps that force more air into the engine. Increased air adds oxygen to the intake charge, producing more power. Turbos have a compressor and turbine wheel connected by a shaft – the exhaust gases spin the turbine, which drives the compressor. Superchargers, however, have only a compressor, which is powered by some connection to the crank, usually a belt.18. A File card.19. C The cement will begin setting immediately, so have each end primed and ready before beginning the cement slather. PVC is easy to glue – no flame, no flux – but don’t dawdle.20. D. And use rope to wrangle dead wood. 21. D Modern engines typically outlast the rest of the car as long as the manufacturer’s service schedule is followed. So do what the book says, but remember: commuting in stop-and-go traffic is considered “severe” duty. 22. A The pickle fork’s forged tines will separate the tie rod ends from the suspension, either by hammering the handle or attaching the handle to an air hammer.23. A Load-bearing walls in the central part of the house run perpendicular to the joists. exterior walls and most stair walls are also load-bearing.24. A Live wires are red.25. C Couplings continue a straight run in pipe or tubing, joining pipes of like sizes or, with a reducer coupling, mating two different diameters.26. B 40 cm.27. C Depending on the belt, the signs of old age include surface cracking – think of the surface of a dry lakebed – and fraying like an unravelling sweater. Modern serpentine belts should last 10 years and 150 000 kilometres. 28. D The multi-monikered hand

tool is critical when installing interior trim. Measure the angle between two walls by pressing each leg against the wall surfaces, lock in the setting, then transcribe the findings to the mitre saw and cut the trim.29. D The blade to cut fibre cement has a tooth geometry unlike the serrated edge of a woodcutting blade. Instead, it contains only about four or five teeth, often made of a high-density carbide and capped with a non-stick coating. Woodcutting blades are perfect for oSB and MDF, and they’re passable for PVC.30. D Ripsaws work like a series of chisels to scoop out material in line with the woodgrain. Crosscut saws sever the wood fibres at each edge of the blade, then the saw teeth scoop out the sawdust in the saw blade’s channel, or kerf. on a 50 x 100, the crosscut saw works across the short side, while the ripsaw cuts along the board’s length.31. A using a roll-pin punch that’s too small will flare the end of the pin and make it even harder to move. The metal in the pin is so hard that it’ll only melt the drill bit. The right punch is nearly as big as the pin. With the punch’s dimpled end centered on the pin, smack the tool smartly with a ball-peen hammer to drive the roll pin out.32. C Tightening the lug nut fractionally, with a torque wrench, lengthens the wheel stud. This maintains the proper clamp force on the wheel. overtighten the nut (likely with a pneumatic wrench) and you risk exceeding the bolt’s yield point, which weakens the metal. Too loose, and the wheel could fall off. 33. D The mullion is a vertical member separating two casement windows, the tympanum is the recessed triangular face of a pedi-ment, the festoon is a decorative fruit or floral carving often found on a frieze, and the nasturtium is an edible flower.34. B For Soss hinges, use a Forstner sized 35 mm. ●

T E S T y o u r D I Y

A n s W E R s

> 1 to 8 .......Dangerous with a drill

> 9 to 16 .....Flirting with competence

> 17 to 25 ...Able to work unsupervised

> 26 to 33 ...Admirably handy

> 34 ............Ready for wrench Mensa

MAkE THE GRADEIf you correctly answered... then you are:

iQ

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p r I c E D TO GO

under r100

TuRn THE KEYgrip’s 13-piece

metric allen key set comes with a

handle (it fits snugly inside the carry case

when closed) that works to provide

extra leverage when using the keys. r92

sTROnG COnnECTORTwisting electrical wires together doesn’t exactly guarantee a quality connection, but soldering connections together most certainly does. ellies’ 30 W soldering iron is just what you need for all those general soldering jobs around the home. r85

DOn’T CRIMP YOuR sTYLE raco’s 5-way crimping tool helps you keep all your electrical work neat and tidy. It strips cables, cuts wires, crimps terminals and even works as a small boltcutter. r70

nIP AnD TuCK Builder’s pride’s 280 mm concrete nipper is just what you need to clean up any jagged edges on cut bricks or tiles. r38

LuBE, WHEn YOu nEED IT MOsTevery workshop needs a can of general

purpose lubricating oil. Fragram’s 300 ml oil can comes with a flexi spout so you

can get into tricky areas. r34

CLEAn CuTTERCutting copper tubing of various diameters is a breeze with topline’s 3-28 mm tubing cutter. r59

okay, I can still afford

r500

AROunD THE BEnDDIY plumbers wanting to lay their own pipes could find rolson’s mini pipe bender indispensable. Made out of lightweight aluminium, it’s capable of bending 6, 8 and 10 mm diameter copper pipes between 0,8 mm and 1,2 mm thick. r220

FORCEFuL PERsuADER

For screws that just won’t budge, raco’s impact driver

is the answer. once struck by a hammer, it will loosen virtually any screw, or tighten

it to extremely high limits. A selector allows for left and right hand rotation. Its 12,7 mm square drive hexagon adaptor

takes interchangeable bits. r230

CuT PERFECT CIRCLEstork craft’s 16 piece hole saw kit helps you cut perfectly smooth, clean and accurate through-holes in wood, plastics and other materials up to 25 mm thick. The kit includes 12 carbon steel hole saws ranging in diameter from 19 to 127 mm, two arbours, one hex wrench and one driveplate. r180

HOT CuTTERWeller’s therma-Boost heat tool can be used for cutting rope or foam, smoothing, shap-ing, scoring and soldering. It heats up to working tempera-ture in 45 seconds and features a thermo-boost trigger to give you additional bursts of power whenever you need them. Also included are six multi-use tips, a stand and instructions. r460

HIDE THOsE jOInTsFor those hidden joints in bookshelves or cabinets pg’s dowelling Jig is just the thing. Included you’ll find the jig, three T spacers (to help you align your workpieces when drilling the dowel holes), as well as various 6 mm, 8 mm, 10 mm and 12 mm diameter dowels. r455

jusT CuT IT OuTIf you want to repair a hole in a dry wall, or cut out any strange shape involving curves for that matter, then you’re going to need Stanley’s versatile 4-way keyhole saw. r120

VERsATILE COMBOIf you need a versatile saw that’s suited to a myriad of jobs, then Stanley’s 300 mm hack/bow saw combo could work for you. r99,99

GET IT squAREWhen you’re welding structures, a right angle means 90 degrees,

no more, no less. The eurasia 90 degree welder’s corner

clamp makes sure all your welded corners are true, no matter what. r230

14 15

Hey,

won’t kill me On THE LEVELSkew tiles are an eyesore. Fortu-nately, Bosch’s new tile laser plt2 makes sure you always lay your tiles with absolute precision. Three vials allow you to align straight or diagonal patterns no walls and floors. Bonus: it comes with a functional baseplate for align-ment in hard-to-reach areas. r560

ROuTInG BLIssIf you like to put your router to good use, then you’ll appreciate tork craft’s 24-piece tungsten carbide-tipped router bit set. All bits can cut hardwood, softwood, medium density fibreboard (MDF) and chipboard. A sealed ball bearing provides smooth cutting of timbers, and all bits can be resharpened. r805

uP THE PREssuRECompressed air often makes jobs such as painting or cleaning up much easier. grip’s 50-litre 1,5 kW compressor is small enough to be moved conveniently around (it weighs 33 kg), yet produces 168 litres per minute and generates 8 bar of pressure. r999

PROjECT WORKHORsEWhenever wooden structures are in the making, the tool that invariably sees the most use is the trusty circular saw. ryobi’s 1 300 W circular saw has a maximum cutting depth of 65 mm at 90 degrees and 43 mm at 45 degrees. You’ll also find a spindle lock for easy blade changes and a lock-off safety switch. A 24-tooth carbide-tipped saw blade is supplied as standard. r600

CORDLEss COnVEnIEnCEBosch’s cordless impact drill pSB 14.4 v-i delivers awesome power and flexibility, even in masonry. It’s also great for screw driving and drilling in wood, metal and plastic. Drilling diameter is 20 mm for wood, and 10 mm for masonry and steel. A convenient carry case is part of the deal. r999

MIGHTY MOusEIf you’re look-ing for a powerful compact driver that can fit into tight spots, then dremel’s 7,2 v lithium-ion cordless driver could be for you. It features a constantly variable speed of 0 – 3 000 r/min, a forward/reverse precision trigger with brake, and a magnetic bit holder with hexagonal shank. It comes with eight bits and a charger. r800

r1 000

COnTOuRED COnTROLBlack and decker’s 6,35 mm KW900e router comes with a three-stage depth stop adjust-ment that enables the recessing of various depths to be machined in one operation, without the usual time-consuming setting up. The circle cutter guide helps you cut perfect circles every time. The edge guide enables parallel cuts to be easily produced, and its dust extraction facility helps you keep your workplace clean. r700

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BITs FOR AnY OCCAsIOnThere’s nothing more irritating than having to down tools to buy a new drill bit when starting a new project. tork craft’s 120 piece drill and Bits set provides you with so many options that you could remain in your workshop for life. You get 13 wood-work bits, 5 wood spade bits, eight mount-ed grinding stones, 18 nut driver bits and 40 25 mm screwdriver bits. The list goes on and on… oh yes, you also get a 300 mm long flexible extension driver. r295

All-in-one solutions

DRIVE IT HOMEScrews come in all shapes and sizes, so logically you need to have enough screw-drivers to match. Stanley’s 20-piece screwdriver set covers the lot: it includes stubbys, stars, flats, offset screwdrivers and a six-piece precision screwdriver set. r285

InsTAnT WOODWORKERIf starting to undertake small woodwork projects sounds like a good idea, but you don’t have any tools yet, then grip’s 10-piece woodwork set is a good place to start. Inside the handy carry pouch you get an aluminium 600 mm spirit level, a half-round 200 mm rasp, two chisels, a claw hammer, a 550 mm hand saw, 5 m measuring tape and two 2-in-1 quick release spreader clamps. r495

FOR THE KITCHEn DRAWEReven if you’re not into DIY, you still need to have some basic tools lying around in a kitchen drawer for the odd emergency around the home. topline’s 15-piece tool Set fits the bill perfectly. You get a claw hammer, junior hacksaw, 5-metre tape measure, utility knife, vice-grips, combination and diagonal cutting pliers, and a combo-screwdriver with bits. r325

POWER TOOLs In A FLAsHWhen you’ve got a circular saw, hand plane and a cordless screwdriver, tackling most woodwork jobs becomes much easier. ryobi’s 3-in-1 combo Kit KSp 3 contains a 650 W hand planer, a 1 300 W circular saw and a 4,8 V cordless screwdriver with magnetic bit holder. The planer has a no-load speed of 16 000 r/min and cuts depths of 0 to 2 mm by 82 mm wide. The circular saw has a 45-degree cutting bevel and a spindle lock, and comes complete with a blade and fence. r950 l

sERIOus KITWith gedore’s complete tool Kit you’re prepared for virtually every eventuality. The strong five-compartment sheetmetal box (phosphated and powder-coated to prevent corrosion) comes packed with quality tools. You’ll find contact drive sockets, combination spanners, Allen keys, screwdrivers, ratchets, grip pliers and more. r3 435

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asked repair or swap-out guarantee for life. other factories in the group are situated in Brazil, Turkey, england, Austria and Germany.

“Because we are a multi-national company we have certain advantages,” says Cykes. “Firstly, all the latest technology from europe is available to us. If there’s an improved way of manufacturing a socket that requires new expensive tooling, we can buy in bulk to lower costs. our engineers are constantly interchanged between factories to ensure we always remain on top of all the latest developments.”

It’s not only tools that they make. Their new sheet metal divi-sion, costing a cool R27 million, produces an extensive range of socket boxes, toolboxes, cupboards and trolleys.

The drop forgeFor obvious reasons, oral communication in the drop forge division (where all the spanners begin to take shape) is impos-sible. “All our staff must have their hearing checked twice a year,” says Cykes as we plug our ears before entering the area.

The first thing that catches the eye is a massive stockpile of chrome vanadium steel awaiting processing. This alloyed steel is ideal for toolmaking because of its strength, toughness and resistance to wear and fatigue. Cropped into suitably sized blanks to minimise waste, the steel is fed into furnaces and heated to between 1 100 and 1 260 degrees (depending on the size of the spanner that’s to be made). once removed from the furnace, the red-hot blanks are placed into a forging die

and then drop-forged into their basic shape. After cooling, any excess material is trimmed off and the products are machined to remove any rough edges. The exact working profiles – hexagon, double hexagon or open end – are broached according to international dimensions and tolerances.

The next process is hardening and tempering. The products are heated to approximately 850 degrees and quenched in a water solution. Tempering follows at a temperature of between 200 and 300 degrees, depending on the product and material. Then the products are allowed to air cool.

Any distortions that may have occurred during hardening are corrected in a straightening process.

Because the teeth of tools such as locking pliers, water-pump pliers and pipe wrenches need to be much harder than the rest of the steel that makes up their bodies, each component undergoes further induction hardening. “We don’t do this to the entire tool because it would then become too brittle, causing it to break when any force gets applied,” explains Cykes.

From this point it’s on to the grinding department for vibro-polishing, and shoulder, ring and shank grinding. After shot blasting, the products are finally sent for a nickel-based chrome electro-plating finish before being packed.

From blank rods to socketsSockets and other accessories are made in much the same way as spanners, except that a mechanical press forge is used. Various diameter blank chrome vanadium steel rods are induction heated until red hot (between 650 and 1 400 degrees, depending on their size) and then press-formed in a bush or die using a mechanical press. The forged blanks are sent to the turning department, where they are faced, turned, knurled and marked automatically on CNC machines.

Next, the products are hardened and treated in a similar manner to the spanners. After shot blasting and polishing, they are nickel chrome plated.

To check out Gedore’s product range, visit www.gedore.co.za l

we head for the factory floor to get the lowdown on tool manufacture

Story and pictures by Sean woods

A bad workman may blame his tools, but it’s no secret that not all tools are created equal. The materials and pro-cesses used can mean the difference between efficient,

precise, repeatable operation and a botch-up. At worst, you could end up with damage to both workpiece and tool.

In fact, where specific tool tolerances are critical – think airlines and motor manufacturers – there’s no room for compromise, so mandatory specifications are laid down. But even for the average DIYer, it pays to get some insight into the background of that shifting spanner that you so carelessly toss into your toolbox.

Let’s go to the source to see how it’s done, we said. So we flew out to New Germany in KwaZulu-Natal, where the Gedore factory is located.

That’s where we found out that shifting spanners are always assembled by hand to make sure that they never “stick” when used. That the teeth of tools such as locking pliers are hard-ened separately. And that the company manufactures SANAS (South African National Accreditation System)-approved torque wrenches for companies such as SAA and Volkswagen SA, where specific tolerances are critically important.

Pound wavesIn the reception area of many companies, it’s not uncommon to find a jar of colourful sweets to tempt visitors and make them feel welcome. At Gedore, they do things slightly differently. Instead, they have a glass jar full of bright yellow ear plugs. And, when their eight massive drop forges start up for the day’s production, you immediately realise why: their incessant, rhythmic pounding bombards the senses. The shock waves reverberate throughout the entire plant and, via the feet, course through your body.

Gedore’s extensive product range comprises 2 900 items, of which about 1 900 are made locally. All adhere to the ISo 9002 international standard. “That means if we make a spanner today it will still be manufactured to the same quality stan-dard next week,” says Vincent Cykes, Gedore’s national sales manager. The company backs that up with a no-questions-

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f I T f o r T H E j O B

Once removed from the furnace, red-hot spanner blanks are placed into a forging die and then drop forged into their basic shape. To give the teeth of tools such as

water-pump pliers extra strength they undergo further induction hardening. All sockets start out as blank sections

of chrome vanadium steel rod. The sockets shortly after being re-

moved from the mechanical press forge. All sockets are broached to ensure

they meet international dimensions and tolerances. After shot blasting and polishing,

sockets are nickel chrome plated. Any rough edges remaining from the

manufacturing process are manually ground away. Tools such as shifting spanners and

locking pliers are assembled individually by hand to make sure they never “stick” when used. Rose stone, imported from Brazil, is

used in the large vibro-polishing vats to polish the finished tools.

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Wire live end

D-shackle

Crosby clip

Thimble

Dead end

S-HookS 1. S-hooks along the railing sup-port pots, pans, colanders and baskets. Spread out the hooks to avoid cookware clang.

Wire ropeS 2. Wire ropes at the corners suspend the rack from the ceiling. Four 3 mm (or thicker) stainless-steel ropes should provide plenty of support for Granny’s cast iron. Chains would also work well, but you might want to paint them to match the rack. either way, the ropes or chains should have a breaking strain of at least 300 kg.

D-SHackleS 3. Wire ropes fasten to the railing using horseshoe-shaped anchor shackles or forged D-shackles. A pin slips into the D-shackle’s opening.

THimbleS 4. The wire rope loops through the D-shackle via a thimble – a curved, grooved track that pre-vents the wire rope from kinking in its u-turn.

Wire-rope clipS 5. Threaded through the thimble, the wire rope fastens to itself us-ing single-saddle Crosby forged wire-rope clips. Make sure that

the clip’s nut side (or saddle) fas-tens to the load-bearing (live) leg of the wire rope. As the Rigging Handbook says, “Don’t saddle a dead horse”.

lag eyebolTS 6. Lag eyebolts with at least 50 mm of wood-screw threads anchor the wire ropes to the ceiling joists (or rawl bolts, if you have a concrete ceiling). Fasten the ropes using Crosby clips and thimbles slipped through each eyebolt. When all four corners are fastened, loosen and tighten the saddle nuts to adjust the ropes one at a time, until the rack is level. l

p M s AT u R D AY

Rust and flaking paint on this salvaged cast-iron railing destined it for the scrap-heap; a steel cup brush scoured it clean in hours. Now, wire ropes suspend it above the island in your country-style kitchen, and every skillet has a home. Do it yourself, using basic tools and a few affordable extras from your local hardware store. We sprayed it matt-black, but you can choose any colour that suits your kitchen.

2 + HALF-DAY PROJECT

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wHAT YOU’LL NEED:l Salvaged or new cast-iron gate/railingl 4 x lag eyebolts or rawl boltsl Stainless-steel cable (or chain)l S-hooks (you can make your own)l D-shacklesl Crosby forged wire-rope clipsl Thimblesl Drill and masonry bitl Steel cut brushl Can of spray paint

scrapyard poT rACk

2323

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2010PO

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www.popularmechanics.co.za

JULY 2010 RSA: R27,95

Other countries: R24,52 excl VAT

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