SHOP EXERCISE 2:

FLATBACK

OBJECTIVES:
1) To be able to manufacture a flatback
2) To be able to understand the concepts of wood processing and providing allowances in
measurements
3) To know how to safely use the tools borrowed from the tool shed

DISCUSSIONS/ANALYSIS

Patterns are mirror images or replicas, usually wooden or plastic, of objects or

components that must be manufactured through casting process. There are different types of
patterns used in casting. One of the types is the single piece pattern which is the most
inexpensive of all the pattern types. It is used in small scale-scale production or prototype
developments. This type of pattern has one side completely flat to prevent complications when
casting a component. A flatback is one of the best examples of single piece patterns. It has one
of its surfaces completely flat and has intricate symmetrical patterns with precise measurements
on the other side. A flatback can be easily produced using different woodworking tools and
techniques.

TOOLS/EQUIPMENT/MATERIALS

1. Pencil
2. Ruler
3. Try Square
4. Backsaw
5. Drill Press
6. Keyhole saw
7. Rasp File
8. Half Round File
9. Small File
10. Triangular File
11. Sandpaper
12. Paintbrush
13. Vernier Caliper
14. N95 Mask
15. Mapua Lab Gown
16. Safety Goggles
17. 120mm x 60mm x 14.50mm Raw Wood
MECHANICAL DRAWINGS

PROCEDURE
Topic Questions

1) What specific tools and equipment did you use during the practical work? Enumerate
and Explain how you used each tool to finish your work.

o Pencil – used to mark the measurements into the material

o Ruler – used to measure the vertical and horizontal measurements
o Try Square – used to measure and mark the 45-degree angle on the material
o Backsaw – used to cut the corners of the material unto the desired shape based
on our marks
o Drill Press – used to drill holes into the inner four corners of the material
o Keyhole saw – used to cut the center of the material through the drilled holes
o Rasp File – used to significantly chip off pieces of the material
o Half Round File – used to fine the chipped off material
o Small File – used to greatly fine the material and into small corners
o Triangular File – used to fine the material especially in the inside corners
o Sandpaper – used to smoothen and finish the product
o Paintbrush – used to brush off saw dust and other particles off our workpiece
o Vernier Caliper – used to accurately measure measurements
o N95 Mask – used to prevent inhalation of saw dust and particles
o Lab Gown – used to protect our body from tools and dust
o Safety Goggles – used to prevent saw dust or particles into our eyes

2) What are the various types of wood that are available in the market today? Enumerate
and define each.

 Kamagong – unique to the Philippines. Produces really dramatic, dark timber. The
grain is grayish and has strong, brown streaks. Not ideal to make whole furniture
pieces.
 Molave – one of the hardest local woods. It has a fine texture which is smooth to the
touch. Ideal for window frames, shipbuilding, and structural posts.
 Tanguile – a hard reddish wood, it is also known as the Philippine Mahogany. It is an
abundant type of wood with fine ribbon or straight grain. Ideal for interior finishes
and cabinets.
 Yakal – a type of mahogany which has resinous wood with yellow to golden-red tones.
It is a high-grade timber that can withstand harsh weathers. Ideal for furniture,
surface finishes, and outdoor construction.
 Acacia – has naturally fine textures and is highly scratch resistant. The grain can either
be straight or wavy and color can range from a light amber to a dark mahogany.
Ideal for boat building, cabinets, and furniture.

3) What is a board foot? Explain

 A board foot is a measurement used by most sawmillers and suppliers in
estimating wood sizes. Its measurement for a piece of lumber is 12" wide by 1' long by
1" thick.

4) What tool or tools can you use when marking the wood? Explain why so.

Marking Knife – it is a knife tool specifically marking wood. It has a sharp edge that is
more accurate than a pencil mark
Pencil – a pencil is a traditional tool in marking wood. It has a lead that marks the wood
with blackish gray color and can be erased.

5) In making the flatback, what is the best way to cut the tapers? Explain your method.

For me personally, the best wat to cut the tapers is to first use the bench vise to
hold the flatback in place. Then, using the rasp file, slowly chip off the side of the
flatback in an upward angle until you have at least a millimeter of allowance above the
marked line. When using the files, hold the tip of the file using one hand and hold the
handle using the other to avoid rounding out the edges. After using the rasp file, use the
half round file to finish and smoothen the tapered side.

6) How can you make a flatback accurately down to the specified dimensions? What
specific steps can you ensure that the final product will be according to the given
dimensions?

To make a flatback with accurate dimensions, first mark all complete

measurements on the raw materials on both sides. Then, using the bench vise, secure
the raw material and cut the corners using a backsaw leaving at least a millimeter or two
of allowance. Note that you should always secure the flatback on the bench vise before
cutting or filing. Then using the drill press, drill the four corners of the inner material,
always leaving a two or more millimeters of allowance. Using the compass saw, cut off
the inner material through the 4 drilled holes. After cutting, chip off excess wood using
the rasp file slowly and always leave an allowance. Lastly, file the flatback into the
desired dimensions. The process of how I file the tapers was explained on question 5.

7) What is another conventional way of determining the correct angle of a workpiece aside
from using a try square? Explain.

A Sliding T Bevel is one of the tools used to mark angles on a wood. It has an
compassing blade that matches any given angle which can be transferred to a
workpiece or measures using a protractor.

8) Why is the bench vise an indispensable tool in the workshop? Explain.

 A bench vise is indispensable because it has a lot of useful uses in the
workshop. It can hold a variety of materials whether it be big, small, heavy, or light. It can
hold workpieces in place as you sand, saw, drill, file, or cut wood, metals and electrical
conduits.

9) What is the difference of a Hack saw, scroll saw, ripsaw and a back saw?

A backsaw is a relatively short saw with a reinforced metal bar on its upper edge
which makes consistently fine straight cuts. A hacksaw is one of the most common types
of saw which are usually used in cutting pipes and tubing. Other than pipes, they can
also cut a variety of materials like wood, metal and plastic using material-specific cutting
blade which you can replace on the hacksaw. A rip saw is a wood saw that is specially
designed for making a rip cut which is a cut made parallel to the direction of the wood
grain. A scroll saw is a powered saw used to make intricate scroll work, spiral lines, or
patterns. It is used for creating curves with edges.

10) How can you draw straight lines on a curved surface of a wood?

You can use other tools in the workshop to draw straight lines on curved surface.
One tool is the tape measure. By aligning the tape measure to the curved surface, you
can easily trace a straight line on the surface by running a pencil along the edge of the
tape measure. Another way of marking a straight line on a dowel, for example, is to use
the miter gauge slot. By placing the dowel on the miter gauge slot, you can run your
pencil along the edge, and it will form a straight line.
CONCLUSION

Our group was able to understand the concept of wood processing and providing
allowances in the measurements and applied to the practical work. Our group proceeded to use
the borrowed tools safely and with precaution. With this said, our group was able to
manufacture a flatback out of the wood which was given.

RECOMMENDATION

When marking the wood, we suggest marking all the complete measurements first on
both side of the wood before cutting to avoid complications later in the work. When it comes to
eye protection, personally, I suggest wearing safety goggles instead of safety glasses as it
tends to fog up whenever you exhale from your mask.

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REFERENCES

Flatback
www.youtube.com/watch?v=Ddh2fup-Zek
www.studiumbook.com/types-of-patterns-single-piece-patternsplit-or-two-piece-pattern-match-
plate-pattern/
www.mechanicalbylokendra.com/types-of-pattern/

Board Foot
www.woodmizer.com/us/Tips-and-How-To/what-is-a-board-foot

Wood Types
www.realliving.com.ph/home-improvement/building-renovating/building-101-types-of-philippine-
hardwood
www.worldinteriors.com/blogs/austin-furniture-roots/acacia-wood-furniture-in-austin

Marking Tools
www.ofwoodworking.com/wood-marking-tools/

Bench Vise
www.gajsupply.com/blog/uses-of-bench-vices/

Saw Types
home.howstuffworks.com/ripsaw.htm
https://www.garagetooladvisor.com/hand-tools/different-types-of-saws-and-their-uses/

Sliding T – Bevel

Straight Line on Curved Surfaces

https://www.youtube.com/watch?v=Ddh2fup-Zek