WOODEN FOLDER

TECHNOLOGY

Year 7/8 - Working time: approximately 5 to 7 double lessons

TASK AND MOTIVATION

During the course of a school year, many teaching materials, such as worksheets and drawings, accumulate during Technology lessons. The wooden folder, made at the beginning of the school year, for example, is used to hold these papers. This creates order and also produces a first workpiece. The hinge and the covers are made of spruce or veneer panels. The rotary movement is provided by round bars. Flow production, and other methods, are possible.

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LEARNING PRIORITIES

  • Specialised and accurate marking
  • Work with hand saws (backsaw, fretsaw) and/or scroll saw as well as a jigsaw (from Year 8, semi-independently)
  • Drill properly with the hand drill and the bench drilling machine (Accident Prevention)
  • Mount the ring binder mechanism
  • Ensure surface glueing - as well as the glueing of dowels - is clean
  • Possibly: Flow production

Wooden folder
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Material and resources

Wooden folder

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Step-by-step plan

Base/cover/corners
Wooden folder

Step 1

Fix the cut-to-size parts of the floor and lid together with painter's tape. Mark the desired radius of the corner rounding with the circular template. Do not select too large a radius (up to max. Ø 25 mm), since otherwise the stapled sheets will protrude.

Step 2

Cut the corners on the cutting saw or with the fretsaw. Work the roundings with the flat file and round off in a "ship swinging movement". Alternatively, this can be done on the plate-grinding machine.

Base/cover: hinged side
Woo

Step 1

Cut the tunrbuckles to size (two short outer parts and one long middle piece).

Wooden folder

Step 2

Remove the adhesive tape from the lid and the floor. Place the short pieces of the swivel blocks on the lid and mark the maximum groove (w = 30 mm, see diagram) at the ends with a pointed pencil.

Wooden folder

Step 3

Cut the upright slits with the backsaw and carry out the longitudinal cut with the scroll/fretsaw.

Wooden folder

Step 4

Place the lid on the floor and transfer the expansion of the groove. Note also that the groove may be a maximum of 30 mm when marking the notches.

Wooden folder

Step 5

Cut out the notches with the backsaw and the decanter/fretsaw.

Swivel blocks: drilling the swivel joint
Wooden folder

Step 1

In order to drill holes as centrally as possible, work with a template or a holding device for the bench drilling machine. Otherwise mark the holes precisely over the diagonals. As boring is done in the forehead, mark the centre point with the pricking awn. Use wooden drills with a centring tip and set the speed at the beginning of the drilling as high as possible (about 3 500 rpm).
Exact right-angled drilling is possible when the drill is aligned parallel to the work piece when it is at a standstill. Then set and limit the maximum drilling depth of 35 mm. The workpieces must be clamped.

Wooden folder

Step 2

When drilling the centre piece, use the hand-held drill if necessary as the size exceeds the maximum working height of the bench drilling machines: clamp the centre piece onto the workbench, align the hand-held drill exactly and allow it to start slowly and with little pressure. A second pupil - looking from the side to the workpiece - helps with the horizontal drilling. If the individual pieces do not fit together later on, re-drill the centre piece with a larger drill (max. diameter 8.5 mm).

Swivel blocks: mounting on base/cover
Wooden folder

Step 1

Use UHU Wood Glue to glue the long swivel block (centre piece) onto the notched base and make sure that the edges on the outer side are flush. Fix the joint with a screw clamp and supports.

Wooden folder

Step 2

Cut the dowel bars during the drying time. Lightly chamfer the ends with the file. Fill the drill holes in the short swivel blocks with some wood glue and press the wooden dowels into the drill holes. The screw clamp can be removed after a drying time of approximately 30 minutes.

Wooden folder

Step 3

Insert the wooden dowels of the short swivel blocks into the centre piece. The subsequent glueing of the lid must be done with good visual judgement and fingertip feeling. Again, the joint must be supported with screw clamps. Since the rotation properties cannot be influenced after the glueing, check that the movement is smooth.

Wooden folder

Step 4

In order to allow a complete opening of the folder, the edges must be slightly rounded or at least be chamfered (plastering or Japanese planes).

Ring binder mechanism: drill hole position, assembly

1. Open the folder and place the ring binder mechanism on the base. The distance between the swivel block and the open ring should be approx. 5 mm. Align in a straight line and mark the drill holes.

2. Drill through the base with a 4 mm drill. If the internal parts are pre-sanded (P 120), assembly can begin.

Surface preparation

The easiest way is to use the folder "naturally", i.e. only the application of wax/oil/coating/varnish is carried out in two separate operations with appropriate intermediate sanding. It is not necessary for the surface to be stained or painted, as this means the assembly process must then be adapted. The surfaces of the individual parts are treated separately and future glueing surfaces must be reserved beforehand with painter's crepe. As a general rule for all paints, varnishes, waxes or oils: Observe the manufacturer's instructions or the technical information sheets and work through them with the pupils.

Name sign or inscription

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©2016 UHU GmbH & Co. KG, Bühl (Baden) and Elke Fox. Photos: Timo Menning and Elke Fox. Drawings: Timo Menning. Editor: Elke Fox.