Lesson 2: Precision Hardware & Mechanical Fastening
Duration of Days: 5
Lesson Objective
SWBAT:
Identify hardware size and thread pitch (Metric vs. Grade 8 Customary) using a thread pitch gauge.
Successfully drill and tap a hole in a 1/4" aluminum plate to secure a vehicle component.
What happens to a race vehicle if the wrong "grade" of bolt is used in the steering rack?
How does the "Tap and Die" process allow us to customize vehicle mounting points?
Tap, Die, Thread Pitch, Torque, Tensile Strength, Grade 8, Metric (M-series), Pilot Hole, Lubricant/Cutting Fluid.
CT-CTE.MFG.B.10: Demonstrate proper use of hand tools.
CT-CTE.TRANS.D.18: Identify and use appropriate fasteners for vehicle repair.
DOK Level: 2 (Application) & 3 (Strategic Thinking)
Students will learn the "nuts and bolts" of vehicle assembly. The purpose is to move beyond "tightening a screw" to understanding torque, thread pitch, and the use of taps and dies to create or repair threads.
Misconception: "All bolts that look the same are equally strong."
Correction: Explain head markings (lines/numbers) that designate the bolt's strength and application
Support: Provide a "Tap Drill Chart" sticker for student notebooks to prevent choosing the wrong pilot bit.
Extension: Students calculate the required torque for a specific bolt size using an engineering table
The Hardware Plate: Students must drill, tap, and bolt three different sized fasteners into a metal plate that passes a "shake test."