AERONAUTICAL STRUCTURE

AND EQUIPMENT FITTER

NSQF – LEVEL 5

1ST Semester

TRADE PRACTICAL

SECTOR: Production & Manufacturing

Draft redacted by YA Group

for AEROCAMPUS Aquitaine
PAGE BLANK
 INTRODUCTION

TRADE PRACTICAL
The trade practical manual is intended to be used in practical workshop. It consists of a series of practical
exercises to be completed by the trainees during the First Semester course of Aeronautical Structure and
Equipment Fitter Trade supplemented and supported by instructions/information to assist in performing the
exercises. These exercises are designed to ensure that all the skills in compliance with NSQF LEVEL - 5
syllabus are covered.

This manual is divided into two modules. The distribution of time for the practical in the four modules are given
below:
MODULE 1: Safety
MODULE 2: Basic fitting operations

The skill training in the shop floor is planned through a series of practical exercise centered around some
practical object. However, there are few instances where the individual exercise does not from a part of project.
While developing the practical manual, a sincere effort was made to prepare each exercise which will be easy
to understand and carry out even by below average trainee. However, the development team accept that there
is a scope for further improvement. We look forward to the suggestions from the experienced training faculty
for improving the manual.

TRADE THEORY
The manual of trade theory consists of theoretical information for the first semester course of the Aeronautical
Structure and Equipment Fitter Trade.
The contents are sequenced according to the practical exercise contained in NSQF LEVEL - 5 syllabus on
Trade Practical. Attempt has been made to relate the theoretical aspects with the skill covered in each exercise
to the extent possible. This correlation is maintained to help the trainees to develop the perceptional capabilities
for performing the skills.
The trade theory must be taught and learnt along with the corresponding exercise contained in the manual on
trade practical. The indications about the corresponding practical exercises are given in every sheet of this
manual.
It will be preferable to teach/learn trade theory connected to each exercise at least one class before performing
the related skill in the shop floor. The trade theory is to be treated as an integrated part of each exercise.
The material is not for the purpose of self-learning and should be considered as supplementary to class room
instruction.

i
 CONTENTS
Exercise
Title of the exercise Page No.
No.
Module 1: Safety
1.1.01 Importance of trade training, list of tools & machinery used in the trade 1
1.1.02 Safety attitude development of the trainee by educating them to use personal 4
protective equipment (PPE)
1.1.03 First aid method and basic training 6
1.1.04 Safe disposal of waste materials like cotton waste, metal chips / burns, etc. 11
1.1.05 Hazard identification and avoidance 12
1.1.06 Safety sign for danger, warning, caution and personal safety message 15
1.1.07 Preventive measures for electrical accidents and step to be taken in such accidents 17
1.1.08 Practice on fire extinguishers 19
1.1.09 Practice and understand precautions to be followed while working in fitting jobs 22
1.1.10 Safe use of tools and equipments used in the trade 25
Module 2: Basic fitting operations
1.2.11 Foreign Object Damage (FOD) and tool inventory 27
1.2.12 Knowledge of the materials used and possible defects 28
1.2.13 Marking out lines, gripping suitably in vice jaws, and hacksawing to given dimensions 30
1.2.14 Sawing different types of metals of different sections 37
1.2.15 Filing flat a large surface and check flatness 41
1.2.16 Filing square and check using engineer square 45
1.2.17 Filing flat, square and parallel to an accuracy of ±0.5 mm 48
1.2.18 Sawing and filing thin aluminium sheet metal 52
1.2.19 Filing steps and notches to accuracy of ±0.5 mm 56
1.2.20 Filing chamfers to an accuracy of ±0.5 mm 60
1.2.21 Filing convex radii 65
1.2.22 Drilling with drill press 71
1.2.23 Make basic adjustment of sheet metal with flanged holes 75
1.2.24 Make countersink, counterbore and spot face 77
1.2.25 Make internal thread 79
Tapping through holes 80
1.2.26 Ream holes with hand reamer 82
Reaming drilled holes using hand reamers 84
1.2.27 Make components to assembly 85
1.2.28 Make assembly with interchangeability 89

ii
 SYLLABUS

First Semester Duration: Six Month

Week Professional Skill Professional Knowledge

Ref. Learning Outcome
No. (Trade Practical) (Trade Theory)

1-2 Recognize & comply with safe 1. Importance of trade training, English technical vocabulary
working practices, environment List of tools & Machinery used in related to the task.
regulation and housekeeping. the trade. All necessary guidance to be
2. Safety attitude development of provided to the newcomers to
the trainee by educating them to become familiar with the working
use Personal Protective of Industrial Training
Equipment (PPE). Institute system including stores
3. First Aid Method and basic procedures.
training. Soft Skills: its importance and Job
4. Safe disposal of waste materials area after completion of training.
like cotton waste, metal Importance of safety and general
chips/burrs etc. precautions observed in the in the
5. Hazard identification and industry/shop floor.
avoidance. Introduction of First aid.
6. Safety signs for Danger, Operation of electrical mains.
Warning, caution & personal Introduction of PPEs.
safety message. Response to emergencies e.g.;
7. Preventive measures for power failure, fire, and system
electrical accidents & steps to be failure.
taken in such accidents. Importance of housekeeping &
8. Use of Fire extinguishers. good shop floor practices.
Introduction to 5S concept & its
application.
Occupational Safety & Health:
Health, Safety and Environment
guidelines, legislations &
regulations as applicable.

3-5 Plan and organize the work to 9. Identification of tools & English technical vocabulary
make job as per specification equipment as per desired related to the task. Aircraft Safety
applying different types of basic specifications for marking & Practices: Foreign Object Damage,
fitting operation and Check for sawing. Inventory of tools before and
dimensional accuracy. 10. Selection of material as per after intervention, Traceability of
application. specific tools used.
11. Visual inspection of raw Linear measurements- its units,
material for rusting, dividers, callipers, hermaphrodite,
scaling, corrosion etc. centre punch, dot punch, their
12. Marking out lines, gripping description and uses of different
suitably in vice jaws, hacksawing types of hammers.
to given dimensions Description, use and care of 'V'
13. Sawing different types of Blocks, marking off table.
metals of different sections.

iii
6-7 Making basic adjustment of sheet 14. Make basic adjustment of English technical vocabulary
metal and Joining techniques for sheet metal using Aluminum2024, related to the task.
sheet metal and metal size 150mm x 150mm, thickness Aircraft Safety Practices:
components. 1.5mm, by performing operations Maintenance of tools, Clean the
of: workstation.
- Tracing by using ruler, Vernier Metallic Material Science:
callipers, Vernier height gauge properties – Physical &
- Cutting process with Hack saw Mechanical
- Deburring (files handling) Non-Ferrous metals: Aluminium
- Checking criteria and acceptance Non-Ferrous Alloys: Aluminium
in accordance with geometric series
tolerances: perpendicularity, Introduction of Engineering
parallelism, flatness, angle Drawing reading plan.
- Appropriate Measuring Introduction of Metrology Vernier
Instrument. [Vernier Calliper, and height gauge handling and
Vernier Height Gauge, Cast Iron maintenance.
surface plates, Vee blocks, File handling, Machining file,
Square, Micrometre] Tracing, Sawing, Vice.
8-10 -do- 15. Make basic adjustment of English technical vocabulary
sheet metal with flanged holes related to the task.
using Aluminium 2024, size 150 Aircraft Safety Practices: Means of
mm x 200 mm, thickness 2 mm, protection of the aircraft working
by performing operations of: area.
- Tracing Metallic Material Science:
- Debiting properties - Physical &
- Deburring Mechanical
- Adjustment of the parts with Non-Ferrous metals: Aluminium
geometric tolerances: Non-Ferrous Alloys: Aluminium
perpendicularity, parallelism, series
flatness, rounded File holding, Machining file,
- Making flanged holes Tracing, Sawing, Vice.
- Appropriate Measuring Bench vice construction, types,
Instrument. [Vernier callipers, uses, care & maintenance, vice
Vernier Height Gauge, Cast Iron clamps, hacksaw frames and
surface plates, Vee blocks, blades, specification, description,
Square, Micrometre] types and their uses, method of
using hacksaws.
Hydraulic press for Flanges holes.

11-13 Produce components by different 16. Adjustment N°1 English technical vocabulary
operations and check accuracy Perform deburring operations on related to the task.
using appropriate measuring a 10mm Aluminium block (Al Human Factors: Human
instruments. 2024), size 100mm x 50 mm, with Performance and Limitations,
geometric constraints (flatness, Social Psychology, Factors
angle, rounded) by: Affecting Performance, Physical
- Tracing by using ruler, Vernier Environment, Physical work;
callipers, Vernier height gauge, Repetitive tasks; Visual
marking blue, Dial comparator inspection; Complex systems,
- Cutting process with Hack saw Communication within and
- Deburring between teams; Human Error,
- Perform adjustment operations Hazards in the Workplace.
with geometric and machining Vertical drill handling and
tolerances: maintenance (counterboring,
- Drilling by using depth gauge countersinking)
and vertical drill machine Marking- Prussian blue, their
- Fitting process by using files special application, description.
- Counterboring Appropriate Use, care and maintenance of
scribing block.

iv
 Measuring Instrument. [Vernier Surface plate and auxiliary
Calliper, Vernier Height Gauge, marking equipment, angle plates,
Cast Iron surface plates, Vee parallel block, description, types,
blocks, Square, Dial comparator, uses, accuracy, care and
Micrometre] maintenance.

14-17 -do- 17. Adjustment N°2 English technical vocabulary

Perform adjustment operations related to the task.
on a 20 mm Aluminium block (Al Human Factors: Brief History of
2024), size 50 mm x 50 mm, with Aviation, General aircraft
geometric constraints by: description, Aerodynamic notions,
- Tracing by using ruler, Vernier, how does an aircraft fly?
height gage, marking blue, dial Counter sink, counter bore and
comparator spot facing-tools and
- Cutting process with Hack saw nomenclature, Reamer- material,
- Deburring types (Hand and machine
- Drilling by using Vernier depth reamer).
gauge and vertical drill machine
- Fitting process (using files)
- Countersinking
- Checking criteria and acceptance
- Appropriate Measuring
Instrument. [Vernier Calliper,
Vernier Height Gauge, Cast Iron
surface plates, Vee blocks,
Square, dial comparator,
Micrometre]
18-20 -do- 18. Adjustment N°3 English technical vocabulary
Perform adjustment operations related to the task.
on a 10 mm Aluminium block (Al Human Factors: Aircraft main
2024), size 50 mm x 50 mm, with parts (fuselage, wing and
geometric constraints by: -Tracing empennage, engine and pylons,
by using ruler, Vernier, Vernier Landing gear, equipment’s) Taps
height gage, marking blue, dial and Thread Standards.
comparator
- Cutting process with Hack saw
- Deburring
- Drilling by using depth gauge
and vertical drill machine-
- Fitting process (using files)
- Reaming
- Countersinking
- Performing thread cutting
- Checking criteria and acceptance
- Appropriate Measuring
Instrument. [Vernier Calliper,
Vernier Height Gauge, Cast Iron
surface plates, Vee blocks,
Square, Dial comparator, " GO no
GO" gauge, Micrometre]

v
21-23 Make different fit of components 19. Adjustment N°4 English technical vocabulary
for assembling as per required Make an assembly (size 100 mm x related to the task.
tolerance observing principle of 50mm) with Aluminium (Al 7075) Metallic Material Science:
interchangeability and check for and Stainless-steel parts of properties - Physical &
functionality. different thicknesses, with Mechanical
geometric constraints by Non-Ferrous metals: Aluminium
performing operations of: Non-Ferrous Alloys: Aluminium
- Drilling series
- Fitting process (using files) Screw threads: terminology,
- Countersinking parts, types and their uses.
- Reaming Screw pitch gauge.
- Performing thread cutting Clearance and tolerances, liquid
- Filling with liquid shim shim handling and maintenance.
(Aluminium filler)
- Clearances measurement.
- Appropriate Measuring
Instrument.
- [Vernier Calliper, Square, Dial
comparator, "GO- no GO" gauge,
Micrometre, Clearance Gauge]

24-26 Revision

vi
 LEARNING/ ASSESSABLE OUTCOME

On completion of this book you shall be able to:

• Recognize & comply with safe working practices, environment regulation and housekeeping.

• Plan and organize the work to make job as per specification applying different types of basic fitting
operation and Check for dimensional accuracy.

• Making basic adjustment of sheet metal and Joining techniques for sheet metal and metal components.

• Produce components by different operations and check accuracy using appropriate measuring
instruments.

• Make different fit of components for assembling as per required tolerance observing principle of
interchangeability and check for functionality.

vii
Production & Manufacturing Exercise 1.1.01
Aeronautical Structure & Equipment Fitter - Safety

Importance of trade training, list of tools & machinery used in the trade
Objectives: At the end of this exercise you shall be able to
• Identify the tools and equipments used in fitter section.
• Record the names of tools, do’s and don’t of each tool.
• rRcord the names of the industries where the fitters are employed.

- - - - - - 1.1.01
[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 1Hr

IDENTIFICATION OF TOOLS,
AND EQUIPMENTS CODE NO.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.1.01 1

 - - - - - - 1.1.01
[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 1Hr

IDENTIFICATION OF TOOLS,
AND EQUIPMENTS CODE NO.

2 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.1.01

Job Sequence
• Trainees will note down all the displayed tools
names, uses and the precaution to be observed
Instructor shall display all the tools and while working with each tool.
equipments in the section and brief their names, • Record it in Table 1.
uses and the safety point to be observed for each • Get it checked by the instructor.
tool and equipment.

Table 1
Precaution to be observed
[Link] Name of tool/equipment Uses
(Do’s and Don’t)

10

11

12

13

14

15

Instructor shall brief the role of a fitter in industries. Emphasis more on

the assembly shop by providing the names of the private and public
sector industries, where the fitters are largely employed. Ask the
trainees to note down the names of the industries.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.1.01 3

Production & Manufacturing Exercise 1.1.02
Aeronautical Structure & Equipment Fitter - Safety

Safety attitude development of the trainee by educating them to use personal

protective equipment (PPE)
Objectives: At the end of this exercise you shall be able to
• Identify personal protective devices.
• Interpret the different types of personal protective devices.
• Identify occupational hazards and the corresponding potential hazards.

- - - - - - 1.1.02
[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 5Hrs

IDENTIFY THE CATEGORIES
OFF PERSONAL PROTECTIVE DEVICE CODE NO.

4 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.1.02

Job Sequence

• Read and interpret the visuals of personal protective

equipment on real devices or from the charts. The instructor shall display the different types of
personal protective equipments or charts and
• Identify and select personal protective equipment
explain how to identify and select the PPE devices
used for different types of protection.
suitable for the work and ask the trainees to note
• Write the name of the PPE and the corresponding down the hazards and type of protection in the
type of protection and the hazards in table 1. Table 1.

TASK 1:

Table 1
[Link]. Name of the PPE Hazards Type of protection
1
2
3
4
5
6
7
8

Get it checked by your instructor.

TASK 2:

• Identify the occupational hazard and the

Instructor may brief the various types of corresponding situation with the potential harm and
occupational hazards and their causes. record it in Table 2.

Table 2
[Link]. Source or potential harm Type of occupational hazards

1 Noise
2 Explosive
3 Virus

4 Sickness
5 Smoking
6 Non control device
7 No earthing
8 Poor house keeping

• Fill up and get it checked by your instructor.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.1.02 5

 Production & Manufacturing Exercise 1.1.03
Aeronautical Structure & Equipment Fitter - Safety

First aid method and basic training

Objectives: At the end of this exercise you shall be able to
• Rescue breathing for an unconscious victim of different condition.
• Perform treatment for stopping of bleeding.

Job Sequence

Assumption - For easy manageability, Instructor

may arrange the trainees in group and ask each
group to perform one method of resuscitation.

TASK1: Prepare the victim to receive artificial 3. Bring the victim safely to the level ground,
respiration taking necessary safety measures.
4. Start artificial respiration immediately without
1. Loosen the tight clothing which may interfere delay. Do not waste too much time in loosening
with the victim’s breathing. the clothes or trying to open the tightly closed
mouth.
2. Remove any foreign materials or false teeth 5. Avoid violent operations to prevent injury to the
from his mouth and keep the victim’s mouth internal parts of the victim.
open. 6. Send word for a doctor immediately.

TASK 2: Resuscitate the victim by Nelson’s arm - Lift

back pressure method

Nelson’s arm-lift back pressure method must not be

used in case there are injuries to the chest and
belly.

1. Place the victim prone (that is face down) with his

arms folded with the palms one over the other and
the head resting on his cheek over the palms. Kneel
on one or both knees near the victim’s hand. Place
your hands on the victim’s back beyond the line of
the armpits, with your fingers spread outwards and
downwards, thumbs just touching each other as in
Fig 1. 2. Gently rock forward keeping your arms straight until
they are nearly vertical, and steadily pressing the

6 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.1.03

 victim’s back as shown in Fig 2 to force the air out of 4. As you rock back, gently raise and pull the victim’s
the victim’s lungs. arms towards you as shown in Fig 4 until you feel
tension in his shoulders. To complete the cycle,
lower the victim’s arms and move your hands up to
the initial position.

3. Synchronise the above movement of rocking

backwards with your hands sliding downwards along
the victim’s arms, and grasp his upper arm just
above the elbows as shown in Fig 3. Continue to
rock backwards.
5. Continue artificial respiration till the victim begins to
breathe naturally. Please note, in some cases, it may
take hours.

6. When the victim revives, keep the victim warm with

a blanket, wrapped up with hot water bottles or warm
bricks; stimulate circulation by stroking the insides of
the arms and legs towards the heart.

7. Keep him in the lying down position and do not let

him exert himself.

TASK 3: Resuscitate the victim by Schafer’s method

2. Kneel astride the victim, so that his thighs are
between your knees and with your fingers and
Do not use this method in case of injuries to victim thumbs positioned as in Fig 5.
on the chest and belly.
3. With the arms held straight, swing forward slowly so
that the weight of your body is gradually brought to
1. Lay the victim on his belly, one arm extended direct bear upon the lower ribs of the victim to force the air
forward, the other arm bent at the elbow and with the out of the victim’s lungs as shown in Fig 6.
face turned sideward and resting on the hand or
forearm as shown in Fig 5.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.1.03 7

4. Now swing backward immediately removing all the
pressure from the victim’s body as shown in Fig 7,
thereby, allowing the lungs to fill with air.

5. After two seconds, swing forward again and repeat

the cycle twelve to fifteen times a minute.

6. Continue artificial respiration till the victim begins to

breathe naturally.

TASK 4: Resuscitate the victim by mouth-to-mouth 4. Take a deep breath and place your mouth over the
method victim’s mouth as shown in Fig 11 making airtight
contact. Pinch the victim’s nose shut with the thumb
1. Lay the victim flat on his back and place a roll of and forefinger. If you dislike direct contact, place a
clothing under his shoulders to ensure that his head porous cloth between your mouth and the victim’s.
is thrown well back. (Fig 8) For an infant, place your mouth over his mouth and
nose.

2. Tilt the victim’s head back so that the chin points

straight upward. (Fig 9)

5. Blow into the victim’s mouth (gently in the case of an

infant) until his chest rises. Remove your mouth and
release the hold on the nose, to let him exhale,
turning your head to hear the rushing out of air. The
first 8 to 10 breathings should be as rapid as the
victim responds, thereafter the rate should be
slowed to about 12 times a minute (20 times for an
infant).

3. Grasp the victim’s jaw as shown in Fig 10, and raise If air cannot be blown in, check the position of the
it upward until the lower teeth are higher than the victim’s head and jaw and recheck the mouth for
upper teeth; or place fingers on both sides of the jaw obstructions, then try again more forcefully. If the
near the ear lobes and pull upward. Maintain the jaw chest still does not rise, turn the victim’s face down
position throughout the artificial respiration to and strike his back sharply to dislodge
prevent the tongue from blocking the air passage. obstructions.

Sometimes air enters the victim’s stomach as

evidenced by a swelling stomach. Expel the air by
gently pressing the stomach during the exhalation
period.

8 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.1.03

TASK 5: Resuscitate the victim by Mouth-to-Nose
method

Use this method when the victim’s mouth will not

open, or has a blockage you cannot clear.

1. Use the fingers of one hand to keep the victim’s lips

firmly shut, seal your lips around the victim’s
nostrils and breathe into him. Check to see if the
victim’s chest is rising and falling. (Fig 12)

2. Repeat this exercise at the rate of 10 - 15 times per

minute till the victim responds.

3. Continue this exercise till the arrival of the doctor.

TASK 6: Resuscitate a victim who is under cardiac 4. Place the palm of one hand on the centre of the
arrest (CPR) cardio pulmanory lower part of the breastbone, keeping your fingers
off the ribs. Cover the palm with your other hand
In cases where the heart has stopped beating, you and lock your fingers together as shown in Fig 15.
must act immediately.

1. Check quickly whether the victim is under cardiac

arrest.

Cardiac arrest could be ascertained by the absence

of the cardiac pulse in the neck (Fig 13), blue colour
around lips and widely dilated pupil of the eyes.

5. Keeping your arms straight, press sharply down on

the lower part of the breastbone; then release the
pressure. (Fig 16)
6. Repeat step 5, fifteen times at the rate of at least
once per second.

2. Lay the victim on his back on a firm surface.

3. Kneel alongside facing the chest and locate the
lower part of the breastbone. (Fig 14)

7. Check the cardiac pulse. (Fig 17)

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.1.03 9

 10. As soon as the heartbeat returns, stop the
compressions immediately but continue with
mouth-to-mouth resuscitation until natural
breathing is fully restored.
11. Place the victim in the recovery position as shown
in Fig 19. Keep him warm and get medical help
quickly.

8. Move back to the victim’s mouth to give two

breaths (mouth-to-mouth resuscitation). (Fig 18)
9. Continue with another 15 compressions of the
heart followed by a further two breaths of mouth-
to-mouth resuscitation, and so on, check the pulse
at frequent intervals.

Other steps

1. Send word for a doctor immediately.

2. Keep the victim warm with a blanket, wrapped up
with hot water bottles or warm bricks; stimulate
circulation by stroking the insides of the arms and
legs towards the heart.

TASK 7: Treatment for bleeding victim

1. Determine the location of the bleeding.

2. Elevate the injured area above the heart if
possible.
3. Apply direct pressure to the bleeding area with
sterile cloth.
4. Keep the pressure on for 5 seconds.
5. Check to see if the bleeding has stopped if not
apply further pressure for 15 minutes.
6. Clean the wound.
7. Bandage the wound with pad of soft material.
(Fig 20)
8. Advice victim to take treatment from doctor.

10 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.1.03

 Production & Manufacturing Exercise 1.1.04
Aeronautical Structure & Equipment Fitter - Safety

Safe disposal of waste materials like cotton waste, metal chips / burns, etc.
Objectives: At the end of this exercise you shall be able to
• Identify and segregate the waste material in workshop.
• Arrange the waste material in different bins.

Job Sequence

• Separate the cotton waste. • Separate the cotton waste material and store it in the
bin provided to store the waste cotton material.
• Collect the chips by hand shovel with the help of (Fig.2)
brush. (Fig.2).
• Similarly store each category of metal chip in
• Clean the floor, if oil is spilled. separate bins.

Do not handle the chip by bare hand Each bin should have name of the material.
There may be different metal chips. So separate the
Identify the material given in fig 1 and fill in
chip according to metal.
table 1

Table1
S No. Name of the material

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.1.04 11

Production & Manufacturing Exercise 1.1.05
Aeronautical Structure & Equipment Fitter - Safety

Hazard identification and avoidance

Objectives: At the end of this exercise you shall be able to
• Identify the occupational hazards.
• Suggest suitable methods to avoid occupational hazards.

- - - - - - 1.1.05
[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 2Hrs

HAZARD IDENTIFICATION AND AVOIDANCE
CODE NO.

12 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.1.05

 - - - - - - 1.1.05
[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 2Hrs

HAZARD IDENTIFICATION AND AVOIDANCE
CODE NO.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.1.05 13

Job Sequence

• Study the drawing of industrial hazards.

The instructor shall emphasise the importance of • Identify the type of hazards.
hazard and avoidance to the students and insist
them to follow properly. • Name the hazards against their names.
• Record the hazards and avoidance in Table 1.

[Link]. Identification of hazards Avoidance

10

• Get it checked by your instructor

14 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.1.05

Production & Manufacturing Exercise 1.1.06
Aeronautical Structure & Equipment Fitter - Safety

Safety sign for danger, warning, caution and personal safety message
Objectives: At the end of this exercise you shall be able to
• Identify the basic categories of safety sign.
• Record the meaning of safety sign in the table given.

- - - - - - 1.1.06
[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 1Hr

IDENTIFY THE CATEGORIES
OF THE SAFETY SIGN CODE NO.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.1.06 15

Job Sequence

• Identify the safety sign from the chart.

Instructor shall provide various safety signs, chart • Record the name of the category in Table 2.
categories and explain their meaning, description.
Ask the trainee to identify the sign and record in • Mention the meaning description of the safety sign
Table 1. in Table 1.

[Link]. Basic Categories/Safety sign Meaning - Description

10

11

12

13

14

15

16

17

18

19

20

• Get it checked by your instructor

16 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.1.06

Production & Manufacturing Exercise 1.1.07
Aeronautical Structure & Equipment Fitter - Safety

Preventive measures for electrical accidents and step to be taken in such accidents
Objectives: At the end of this exercise you shall be able to
• Rescue a person from live wire.

- - - - - - 1.1.07
[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 2Hrs

PREVENTIVE MEASURES FOR ELECTRICAL
ACCIDENTS CODE NO.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.1.07 17

Job Sequence

3. Move the victim physically to a nearby place.

Disconnecting a person (mock victim) from a live supply 4. Check for the victim’s natural breathing and
(simulated) consciousness.
5. Take steps to apply respiratory resuscitation if the
1. Observe the person (mock victim) receiving an victim is unconscious and not breathing.
electric shock. Interpret the situation quickly.
2. Remove the victim safely from the ‘live’ equipment
by disconnecting the supply or using one of the
items of insulating material.
Do not run to switch off the supply that is far away.
Do not touch the victim with bare hands until the
circuit is made dead or the victim is moved away
from the equipment.
Push or pull the victim from the point of contact of
the live equipment, without causing serious injury
to the victim. (Fig.1)

18 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.1.07

Production & Manufacturing Exercise 1.1.08
Aeronautical Structure & Equipment Fitter - Safety

Practice on fire extinguishers

Objectives: At the end of this exercise you shall be able to
• Select the fire extinguisher according to the type of fire.
• Operate the fire extinguisher.
• Extinguish the fire.

- - - - - - 1.1.08
[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 7Hrs

PRACTICE ON FIRE EXTINGUISHER
CODE NO.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.1.08 19

Job Sequence

• Alert people surrounding by shouting fire, fire, fire

when observe fire.
Do not allow people to go nearer to the fire.
• Inform fire service or arrange to inform immediately.
• Open emergency exit and ask them to go away.

Table 1
Class ‘A’ Wood, paper, cloth, solid material

Class ‘B’ Oil based fire (grease, gasoline, oil) &

liquefiable solids

Class ‘C’ Gas and liquefied gases

Class ‘D’ Metals and electrical equipment

• Pull the safety pin from the handle (Fig 2) (Pin

located at the top of the fire extinguisher) (Fig 2)
Assume the fire is 'B' type (flammable liquefiable
solids). • Aim the extinguisher nozzle or hose at the base of the
fire (this will remove the source of fuel fire) (Fig 3)

• Select CO2 (carbon dioxide) fire extinguisher

Keep yourself low.
• Locate and pick up CO2 fire extinguisher. Check for
its expiry date.
• Break the seal. Fig1

20 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.1.08

 Caution
• While putting off fire, the fire may flare up.
• Do not be panic so long as it put off promptly
• If the fire doesn't respond well after you have used
up the fire extinguisher move away your self away
from the fire point.
• Do not attempt to put out a fire where it is emitting
toxic smoke, leave it to the professionals.
• Remember that your life is more important than
property.
So, don't place yourself or others at risk.

In order to remember the simple operation of

fire extinguisher
Remember
P.A.S.S. This will help to use fire extinguisher.
• Squeeze the handle lever slowly to discharge the
agent (Fig 4)
P for pull
• Sweep side to side approximately 15 cm over the
A for aim
fuel fire until the fire is put off. (Fig 4)
S for squeeze
S for sweep
Fire extinguishers are manufactured for use from
the distance.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.1.08 21

Production & Manufacturing Exercise 1.1.09
Aeronautical Structure & Equipment Fitter - Safety

Practice and understand precautions to be followed while working in fitting jobs

Objectives: At the end of this exercise you shall be able to
• Record the precaution to be followed while working in fitting jobs.

- - - - - - 1.1.09
[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 2Hrs

PRECAUTIONS WHILE
WORKING IN FITTING JOBS CODE NO.

22 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.1.09

 - - - - - - 1.1.09
[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 2Hrs

PRECAUTIONS WHILE
WORKING IN FITTING JOBS CODE NO.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.1.09 23

Job Sequence

• Record the precautions to be followed while working

The instructor shall guide and demonstrate the in fitting job in Table 1
students to practice and understand precautions to
be followed while working in fitting jobs.

Table 1
Record precautions to be followed while
[Link]. Description
working in fitting job

10

• Fill up and get it checked by your instructor.

24 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.1.09

Production & Manufacturing Exercise 1.1.10
Aeronautical Structure & Equipment Fitter - Safety

Safe use of tools and equipments used in the trade

Objectives: At the end of this exercise you shall be able to
• Record the safety points while using the fitter trade tool and equipments.

- - - - - - 1.1.10
[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 2Hrs

FITTER TOOLS AND EQUIPMENTS
CODE NO.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.1.10 25

Job Sequence

The instructor shall emphasise the students about • Record the precautions to be followed while working
the safe use of tools and equipments used in trade in fitting job in Table 1
and guide them to record the safety points

Table 1
Record precautions to be followed while
[Link]. Description
working in fitting job

10

• Fill up and get it checked by your instructor.

26 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.1.10

Production & Manufacturing Exercise 1.2.11
Aeronautical Structure & Equipment Fitter – Basic fitting operations

Foreign Object Damage (FOD) and tool inventory

Objectives: At the end of this exercise you shall be able to
• Identify the FOD.
• Record the FOD found correctly.
• Make the tool inventory.

Job Sequence

TASK 1

The instructor will present the different types of Trainees will:

FODs and the damage they may cause. He shall put
five FODs in the toolboxes. • note down the FODs found in the tool box
He will ask the trainees to look for them and write • record them in Table 1.
them down in Table 1. The instructor will check for correctness.

Table 1

[Link] FOD found Origin / How to avoid

Fill up and get it checked by your instructor.

TASK 2

Trainees will:
The instructor will brief trainees on the different • make the inventory and put away the tools.
tools used and suggest how to arrange them in the • complete the inventory sheet.
toolbox. He will provide the trainees with the
inventory sheet and explain how to complete it. The instructor will check the inventory sheet and
arrangement of the tools

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.11 27

 Production & Manufacturing Exercise 1.2.12
Aeronautical Structure & Equipment Fitter – Basic fitting operations

Knowledge of the materials used and possible defects

Objectives: At the end of this lesson you shall be able to
• Identify the materials and their shape.
• Visually inspect the material.
• Name the damage correctly.

Job Sequence

• Observe the given material

The instructor will brief the trainees on the
• Identify the material by visual observation
different types of material and shapes. He will
• Record the materials in Table 1. Get it checked by display 10 different sections of raw metals in
the instructor various shapes.
The instructor will ask the trainees to record the
materials and shapes in the table

TASK 1:
Table 1
[Link]. Material Shape

10

Get it checked by your instructor.

28 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.12

TASK 2:

• Observe the damaged material

The instructor will brief the trainees on the
different types of defects and damages. He will • Identify the damage by visual observation
show 10 different damaged parts and ask the
• Record the damage in Table 2.
trainees to record them in the table
• Get it checked by the instructor

Table 2

[Link]. Defect/damage

10

Fill up and get it checked by your instructor.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.12 29

Production & Manufacturing Exercise 1.2.13
Aeronautical Structure & Equipment Fitter – Basic fitting operations

Marking out lines, gripping suitably in vice jaws, and hacksawing to given dimensions
Objectives: At the end of this exercise you shall be able
• Mark out lines using a jenny calliper.
• Hold the workpiece in a bench vice.
• Cut along marked lines.

1 60 x 60 x 5 - Fe310 PRE-MACHINED - TASK-2 1.2.13

1 60 x 60 x 5 - A2017 PRE-MACHINED - TASK-1 1.2.13
[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 10Hrs

MARKING AND SAWING
CODE NO.

30 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.13

Job Sequence

TASK 1: Marking and hacksawing steel

• Check the dimensions of the pre-machined • Set the jenny calliper to 22 mm using a steel rule.
workpiece using a steel rule: 60x60x5 mm
• Draw a line parallel to the "BC" side using the jenny
• Place the workpiece in the surface plate. calliper as shown in Fig 3.
• Set the jenny calliper to10 mm using the steel rule. Fig 3

• Draw a 10-mm-long line parallel to the “AB” side with

the jenny calliper as shown in Fig 1.
• Similarly, set the jenny calliper to 22 mm, 38 mm and
50 mm and draw lines parallel to "AB" (Fig 1).
Fig 1

• Hold the workpiece firmly in the bench vice, keeping

the "AD" side parallel to the vice Jaws.
• Select a 1-mm pitch hacksaw blade, fix the blade in
the hacksaw frame, with the teeth pointing forward.
• Set the jenny calliper to 22 mm using a steel rule. • Tighten the blade to the required tension with the
• Draw a line parallel to the "AD" side using the jenny wing nut.
calliper. • File a notch at the point in which the hacksaw is
• Similarly, set the jenny calliper to 30 mm and 45 mm placed to avoid slippage of the blade.
and draw lines parallel to the "AD" side as shown in • Start cutting with a slight downward pressure using
Fig 2. the hacksaw.
Fig 2 • Saw along the lines.
• Apply pressure in the forward stroke.
• Release the pressure in the return stroke.
• Use the full length of the blade while sawing.
• Check the size with a steel rule.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.13 31

TASK 2: Marking and hacksaw cutting Fig 3

• Check the dimensions of the pre-machined

workpiece using a steel rule: 60x60x5 mm.
• Place the workpiece on the surface plate.
• Set the jenny calliper to 15 mm using a steel rule.
• Draw a 15-mm-long line parallel to the "AB" side
using the jenny calliper (Fig 1).
• Repeat the previous steps and draw 15-mm lines
parallel to "BC", "CD", and "AD" As shown in Fig 1.
Fig 1

Cut close to the line. Ensure that the line is visible

while sawing.

• Without changing the position of the workpiece cut

the line from point 3 to point 4, keeping the hacksaw
on the left side of the line.
• Similarly, turn the workpiece and cut the line from 5
to 4, 6 to 7, 8 to 7, 9 to 10, 11 to 10 and 12 to 2.
• Set the jenny calliper to 35 mm (15+20) using a steel • After sawing the workpiece (Fig 4), check the size
rule. with a steel rule.
• Draw a 35-mm line parallel to the “BC” and “CD”
sides using the jenny calliper as shown in Fig 2.
Fig 4
Fig 2

• Hold the workpiece firmly in the bench vice, keeping

the “AD” side parallel to the vice jaws.
• Start cutting on the "AD", cut the line from point 1 to
2, keeping the hacksaw on the right side of the line
(Fig 3).

32 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.13

Skill Sequence

Measuring with a steel rule

Objectives: This shall help you to
• Measure lengths.

Place the rule either directly on to the length to be For correct measurements hold the rule parallel to the
measured or at a right angle to the reference plane. edge of the workpiece (Fig 3).
Use a straight contact face if possible (engineer’s Fig 3
square, surface block, Vee block, etc.) and read off
measurements by looking at the steel rule directly. (Fig
1)
Fig 1

You can also measure with a rule starting off from the
centimetre line (Fig 2).

Fig 2

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.13 33

 Marking lines parallel to the edge with a jenny calliper
Objectives: This shall help you to
• Mark parallel lines using a jenny calliper.

Apply marking medium on the surface to be marked. Transfer the set dimension to the workpiece. (Fig 2)
Set the jenny calliper to the size to be marked (i.e. Fig 2
dimension) with a steel rule (Fig 1).

Fig 1

Incline slightly and move the jenny calliper with uniform

speed and mark lines.

34 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.13

 Clamping the workpiece in the bench vice to sawing
Objectives: This shall help you to
• Clamp a workpiece firmly in a bench vice.
• Clamp a workpiece without damaging the edges and surfaces.

A bench vice is used to clamp the workpiece in the Fig 3

required position to perform different operations such as
cutting, filling, etc.
• Check the height of the bench vice. For ease in
working, the recommended height of the bench vice
is shown in Fig 1.

Fig 1

• Set the correct position of the workpiece. Hold the

workpiece in the bench vice with a minimum
projection from the top of the vice jaw without
touching the vice (Fig 4).
• Close the jaws of the bench vice to tighten the
workpiece lightly by turning the handle in clockwise
direction (Fig 1).
Fig 4
• Open the jaws of the bench vice by turning the
handle in anticlockwise direction, wide enough to
place the workpiece in between the jaws (Fig 2).
• Use soft metal like aluminium angle (B) to protect the
surface of the workpiece from damage by the hard
jaws (A) (Fig 3).
Fig 2

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.13 35

 Sawing along a line
Objectives: This shall help you to
• Cut along a straight line by hacksaw.

Clamp the workpiece on the vice and make sure that the Hold the hacksaw properly at an angle of 5 to 30° (Fig
marked sawing line is close to the side of the vice jaws 2).
to achieve maximum firmness.
Fig 2
Tighten the jaws firmly to avoid tilting and shifting of the
workpiece.
If the section being cut shows chattering effect or
vibration, the clamping needs to be improved.
Select the correct pitch blade for cutting.
The shorter the cutting section is, the finer the blade
pitch that needs to be used. Make sure that at least 3
teeth are cutting at a time.
The harder the material the finer the blade pitch should
be.
Fix the blade so that the teeth are in the direction of the
cut.
Tighten and tension the blade by hand using only the
wing nut.
Apply a little downward hand force so that only a few
teeth are cutting. Press down only during the forward
Caution (cutting) stroke.
Insufficient blade tension > the cut will not be
straight. Use the full length of the blade to avoid early dulling of
Too much tension > the blade will break. the teeth in the middle portion of the blade.
Move the blade strictly in line with the marked direction.
Do not tilt the frame while sawing because bending of
Make a notch at the starting point on a smooth and hard the blade can cause sudden breakage of the blade.
material to prevent the hacksaw from slipping (Fig 1).
Resort to cutting from the opposite side if the deviation
from the marked line is excessive.
Fig 1 Fig 3

Slow down the cutting while completing the cut to

avoid breakage of the blade and injury to yourself.

36 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.13

Production & Manufacturing Exercise 1.2.14
Aeronautical Structure & Equipment Fitter – Basic fitting operations

Sawing different types of metals of different sections

Objectives: At the end of this exercise you shall be able
• Cut metals of different thicknesses.
• Cut sections of metals.

1 Æ32 – 100 mm - Fe310 TASK 3 1.2.14

1 30 x 30 x 3 – 100 mm - 2017 - TASK-2 1.2.14
1 Æ30 – 100 mm - Fe310 - TASK-1 1.2.14
[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 10Hrs

HACKSAWING IN DIFFERENT TYPES OF METALS
CODE NO.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.14 37

Job Sequence

TASK 1: Sawing on steel round bar (rod) • Cut on the hacksawing line while applying the proper
pressure on the forward and return strokes. Use the
• Check the dimensions of the raw material using a
full length of the blade.
steel rule: Ø30 x 100 mm
• The cutting movement should be steady while
• Apply marking media only where marking is
sawing the round rod.
required.
• While finishing the cut, slow down the pressure to
• Place the round rod on the levelling plate.
avoid breakage of the blade and injury to yourself
• Use a 'V' Block to support the round rod while and others.
marking it with a surface gauge.
• Check the size of the round rod with a steel rule.
• Hold the workpiece in the bench vice.
• Fix a 1.8-mm pitch hacksaw blade in a hacksaw Selection of hacksaw blade
frame. For soft materials use a 1.8-mm pitch blade for
sawing.
• File a notch at the point where the hacksaw is placed
For hard materials use a 1.4-mm pitch blade for
to prevent the blade from slipping.
sawing.
• Start cutting the round rod using the hacksaw while
applying a slight downward pressure.

TASK 2: Sawing on aluminium angle • Check the size of the angles with a steel rule.
• Check the dimensions of the raw material using a
steel rule: aluminium angle 30x30x3 – 100 mm. Caution
• Mark the sawing lines. Select the correct pitch blade according to the shape
and materials to be cut.
• Hold the workpiece in the bench vice as shown in While sawing, three or more teeth of the blade
Figure.1 should be in contact with the metal section.
• Fix a 1.8-mm coarse pitch blade in the hacksaw
frame.
• Cut along the sawing lines with the hacksaw.

TASK 3: Sawing on steel pipe • Check the size of the pipe with a steel rule.
• Check the dimensions of the raw material using a
steel rule: steel pipe to size Ø32 x 100 mm. Caution
• Mark the sawing lines. Avoid over tightening the pipe in the vice which
cause deformation.
• Hold the workpiece in the bench vice as shown in Do not cut too fast.
Fig 1. Cut slowly and reduce pressure while cutting
through.
• Fix the 1.0-mm pitch blade in the hacksaw frame
• Cut along the sawing lines with the hacksaw.
• Turn and change the position of the pipe while hack
sawing.

38 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.14

 Marking in a cylindrical part
Objectives: This shall help you to
• Mark in cylindrical parts using a Vee block and a surface gauge.

Hold the workpiece on the Vee block. Fig 1

Set the surface gauge to the size to be marked (i.e.

dimension) with a steel rule.
You can also mark the dimension on the workpiece and
set the surface gauge to this mark.

Transfer the set dimension to the workpiece by moving

the surface gauge around the part or by rotating the
workpiece (Fig 1).

Marking in an angle
Objectives: This shall help you to
• Mark in an angle using an engineer’s square.

Mark the dimension with a steel rule. Trace the line (Fig 2).
Position the square on the angle (Fig 1).
Fig 1 Fig 2

Trace the line.

Position the square on the other flange of the angle in
alignment with the line.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.14 39

 Hacksawing (holding-pitch selection)
Objectives: This shall help you to
• Cut along a straight line in a different shape by hacksaw.

Depending on the shape of the workpiece to be cut,

holding it in position in the vice is important.
Fig 2
The cutting angle will also be chosen according to the
shape.

Choose the blade pitch and the cutting angle so that

there are always at least 3 teeth in contact with the
workpiece.

Position the workpiece in the vice with the marked line

as close as possible to the jaws.
Make a notch at the starting point to prevent the
hacksaw from slipping.

Fig 1

Slow down the cutting while completing the cut to

avoid breakage of the blade and injury to yourself.

40 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.14

Production & Manufacturing Exercise 1.2.15
Aeronautical Structure & Equipment Fitter – Basic fitting operations

Filing large flat surface and check flatness

Objectives: At the end of this exercise you shall be able
• File flat with straight file or rasp.
• Check flatness with straight rule.

1 60 x 60 x 20 - A2017 - TASK-1 1.2.15

[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 2Hrs

FILING LARGE FLAT SURFACE AND CHECK
FLATNESS CODE NO.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.15 41

Job Sequence

• Hold the workpiece in the bench vice. Fig 1

• File with file by crossing filing the surface ‘A’.

• Check the flatness regularly.
• Finish the surface by cross filing.
• Deburr edges.

Skill Sequence

Clamping the workpiece in the bench vice to filing

Objectives: This shall help you to
• Clamp a workpiece firmly in a bench vice.
• Clamp a workpiece in good position.

Set the correct position of the workpiece. Fig 1

• Hold the workpiece in the bench vice with a

minimum projection from the top of the vice jaw
without touching the vice.
• The workpiece must be in the centre of the jaws.
• Hold the workpiece parallel to facilitate the flat filing.
• Close the jaws of the bench vice to tighten the
workpiece lightly by turning the handle in clockwise
direction.

42 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.15

 Filling flat
Objectives: This shall help you to
• File flat.

Check whether the handle of the file fits tightly. Hold the For light filing. (Fig 3)
handle of the file (Fig 1) and push the file forward using
Fig 3
your right hand palm on left hand palm.
Fig 1

Hold the tip of the file according to the quantity of the

metal to be removed.
Start filing by pushing the file uniformly during the For removing local unevenness. (Fig 4)
forward stroke and release the pressure during the Fig 4
return stroke.
Continue giving strokes. Balance the pressure of the file
in such a way that the file always remains flat and
straight over the surface to be filed.

For heavy filing. (Fig 2)

Fig 2

Cross filling
Objectives: This shall help you to
• File by cross filing.

In this method of filing, the file is run across the

workpiece, which is from left to right or right to left. Thus,
File all the surface with an angle of 45° approximately.
filing is done diagonally.
(Fig 1)
In this method, curves in work pieces can be minimized.
Maximum material can be removed due to the cross
marks of files. The whole surface of job is covered in a
stroke.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.15 43

Fig 1 Fig 2

Change the angle of the file and file all the surface.
(Fig 2).

Check flatness with bevelled straight edge

Objectives: This shall help you to
• Check flatness of a surface.

During filing, the surface can be visually observed to a Fig 2

reasonable degree of perfection.
To ensure perfection, the surface should be checked with
a beveled straight edge.

Put the straight edge in different areas on the surface in

different angles. (Fig 1 and 2)

Do not slide the straight edge against the workpiece

to avoid damaging the tool.

Note: the blade of a square can serve as a straight edge.

Burrs should be removed before any checking.

Fig 1

44 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.15

Production & Manufacturing Exercise 1.2.16
Aeronautical Structure & Equipment Fitter – Basic fitting operations

Filing square and check using engineer square

Objectives: At the end of this exercise you shall be able
• File flat and square with straight file or rasp.
• Check the squareness with engineer square.

1 60 x 60 x 20 > 1.2.15 A2017 - TASK-1 1.2.16

[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 4Hrs

FILING SQUARE AND CHECK SQUARENESS
CODE NO.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.16 45

Job Sequence

• Hold the workpiece in the bench vice. Fig 1

• File flat and straight the surface ‘A’.

• Check the flatness and squareness.
• File flat and straight the surface ‘B’.
• Check the squareness with the surface ‘A’.
• File flat and straight the surface ‘C’.
• Check the squareness with the surface ‘B’.
• File flat and straight the surface ‘D’.
• Check the squareness with the surfaces ‘A and ‘C’.
• Finish the four surfaces by draw filing.
• Deburr edges.

Skill Sequence

Draw filling
Objectives: This shall help you to
• File by draw filing.

In this method of filing, files are handled by both hands Fig 1

on the file.
File is placed at right angle to the surface of work piece.
(Fig 1)

This method doesn’t remove material faster but gives

better finish than straight or cross filing.

46 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.16

 Check squareness with engineer square
Objectives: This shall help you to
• Check squareness of an angle.

To ensure perfection, the squareness should be checked Second method: using the square on the surface
with a square. plate

Light gap will indicate the high and low spots. Put the part on the surface plate and one face on the vee
block (or an angle plate) to hold the workpiece in position
as shown in Fig. 02.
First method: using the square only
Check with a square.
While checking with a square, press the stock
against the reference and then slowly bring down the
blade (Fig. 01). Fig. 02

Fig. 01

Burrs should be removed before checking.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.16 47

Production & Manufacturing Exercise 1.2.17
Aeronautical Structure & Equipment Fitter – Basic fitting operations

Filing flat, square and parallel to an accuracy of +/-0.5mm

Objectives: At the end of this exercise you shall be able
• File flat, square and parallel with straight file or rasp.
• Tracing with surface gauge.
• Check dimension with vernier calliper.

1 60 x 60 x 10 A2017 - TASK-1 1.2.17

[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME64Hrs

FILING FLAT, SQUARE AND PARALLEL WITH AN
ACCURACY OF +/-0.5 CODE NO.

48 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.17

Job Sequence

• Check the raw material size using steel rule. Fig 1

File references - Fig 1

• File flat and straight the surface ‘A’.
• File surface ‘B’ perpendicular to ‘A’.
• Check flatness and squareness.
• Deburr edges.

File dimensions - Fig 2

• Mark surface ‘C’ and ‘D’ to size 58x58mm using
surface gauge or vernier height gauge.
• File side ‘C’ and ‘D’ by maintaining the size ±0.5mm.
Fig 2
• Check size with vernier calliper.
• Check flatness and squareness.
• Finish the four surfaces by draw filing.
• Deburr edges.

File dimensions - Fig 3

• File flat the surface ‘E’.
• Finish by cross filing.
• Check flatness.
• Mark sides to size 8mm.
• File opposite side to ‘E’ by maintaining the size
±0.5mm.
Fig 3
• Finish by cross filing.
• Deburr edges.
• Check size with vernier calliper.
• Check flatness.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.17 49

Skill Sequence

Marking parallel lines using surface gauge

Objectives: This shall help you to
• Mark parallel lines using a surface gauge.

Check the free movement of the scriber and other sliding Apply a thin and even coating of the marking media.
units. Butt the job against the angle plate.
Clean the base of the surface gauge. Hold the job in one hand and move the scriber point
touching the surface across the work and mark. (Fig 2)
Keep the base firmly on the surface plate.
Rest the steel rule against the angle plate and set the
scriber to the size to be marked. (Fig 1) Fig 2

Fig 1

Make sure that the job has no burrs and has been
properly cleaned.

50 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.17

 Marking with a vernier height gauge
Objectives: This shall help you to
• Mark with a vernier height gauge.

What is the main function of the vernier height Keep the vernier height gauge base firmly on the surface
gauge? plate.
One of the primary functions of the vernier height gauge Hold the scriber at an angle to the workpiece and pull the
is to scribe lines on a workpiece to known heights. corner of the scriber across the work. (Fig.2)

How to use a vernier height gauge? Fig 2

The height gauge scriber must be checked against the
reference surface to confirm whether the zero of the
vernier coincides with the zero of the beam scale when
the scriber contacts the reference surface. (Fig.1)

Check for free movements of the sliding unit.

Make sure that the workpiece has no burr and has been
properly cleaned.

Fig 1

Do not allow the base to lift.

Do not apply too much pressure to peel off metal from

the workpiece. This will avoid damage to the scriber
point.

Scribe first all lines of dimensions in one direction.

Ensure the scriber point is always sharp.

Burrs should be removed before checking.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.17 51

Production & Manufacturing Exercise 1.2.18
Aeronautical Structure & Equipment Fitter – Basic fitting operations

Sawing and filing thin aluminium sheet metal

Objectives: At the end of this exercise you shall be able
• Mark out lines using a jenny calliper.
• Cut along marked lines.
• File thin sheet metal to give dimension.

Quantity: 4

1 150 x 150 x 1.5 - A2024 - TASK-1 & 2 1.2.18

[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 10Hrs

MARKING AND SAWING
CODE NO.

52 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.18

Job Sequence

TASK 1: Marking and hacksawing Fig 2

• Check the dimensions 150x150x1.5 mm

• File the four surfaces “AB”, “BC”, “CD” and “DA” by
draw filing.
• Check flatness and deburr edges.
• Place the workpiece in the surface plate.
• Set the jenny calliper to 73 mm using the steel rule.
• Draw a 73-mm-long line parallel to the “AB”, “BC”,
“CD” and “DA” side with the jenny calliper as shown
in Fig 1.
Fig 1

• Select a 1-mm pitch hacksaw blade, fix the blade in

the hacksaw frame, with the teeth pointing forward.
• Tighten the blade to the required tension with the
wing nut.
• File a notch at the point in which the hacksaw is
placed to avoid slippage of the blade.
• Start cutting with a slight downward pressure using
the hacksaw.
• Saw between the lines.
• Apply pressure in the forward stroke.
• Release the pressure in the return stroke.

• Hold the workpiece firmly in the bench vice between • Use the full length of the blade while sawing.
two pieces of wood (Fig 2). • Check the size with a steel rule.

TASK 2: Filing thin workpiece Fig 1

• Set the workpiece in the bench vice.

• File side 1 and 2 parallel and square with others.
• Check flatness, squareness and deburr edges.
• Check the dimension with steel rule.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.18 53

 Filing a thin surface using rasp
Objectives: This shall help you to
• File surfaces flat using a rasp

Hold the handle of the file (Fig 1). Start filing by pushing the rasp uniformly during the
The right hand holds the handle while the left hand holds forward stroke and release the pressure during the return
and orients the rasp by its tip. stroke.
The rasp slides along the edge as shown in Fig 3.
Fig 1 Release the pressure on the rasp at the end of the part.

Fig 3

Put the rasp on the edge to adjust with angle 15° to 20°
(Fig 2).

Fig 2

54 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.18

 Checking a flatness of the edge
Objectives: This shall help you to
• Check the flatness of the edge.

During filing, the surface can be visually observed to a Fig 2

reasonable degree of perfection.
To ensure perfection, the surface should be checked with
a beveled straight edge.
Note: the blade of a square can serve as a straight edge.
Burrs should be removed before any checking.

Fig 1

Deburring the sharp edge

Objectives: This shall help you to
• Deburr edges in thin metal sheet

The filling process produces burrs. Fig 1

In order to avoid cuts and incorrect measurements, burrs
must be removed.

Preferably use a deburring tool that can be used by

pulling. Be careful not to scratch the part with the other
parts of the tool (Fig. 01).

Deburring is only performed to remove the formed burr,

not to make a chamfer.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.18 55

Production & Manufacturing Exercise 1.2.19
Aeronautical Structure & Equipment Fitter – Basic fitting operations

Filing steps and notches to accuracy of ±0.5 mm

Objectives: At the end of this exercise you shall be able
• Sawing and filing steps and notches.
• Tracing with vernier height gauge.
• Check dimension with vernier calliper and vernier depth gauge.

TASK 1

1 60 x 60 x 10 A2017 - TASK-1 1.2.19

[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME6Hrs

FILING STEPS AND NOTCHES WITH AN ACCURACY
OF +/-0.5 CODE NO.

56 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.19

 TASK 2

1 73 x 73 x 1.5 > 1.2.18 A2024 - TASK-2 1.2.19

[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME6Hrs

FILING STEPS AND NOTCHES WITH AN ACCURACY
OF +/-0.5 CODE NO.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.19 57

Job Sequence

TASK 1: Steps in thick sheet metal

• Check the raw material size using steel rule. Fig 1

File references
• File flat and straight by draw filing the 4 surfaces.
• Check flatness and squareness.
• Deburr edges.

Marking - Fig 1
• Mark the steps with vernier height gauge as per
drawing.

Sawing and filing the first step - Fig 2

Fig 2
• Cut and separate the excess material by sawing.
• File the step with safe edge file using bastard,
second cut and smooth grades maintaining the
accuracy of ± 0.5 mm.
• Measure the job sizes with vernier calliper and
vernier depth gauge.
• Check the squareness with square

Sawing and filing the second step - Fig 3

• Similarly, cut and separate the excess material by
sawing. Fig 3
• File step with safe edge file using different grades
maintaining the accuracy of ± 0.5 mm.
• Measure the job size with vernier calliper and vernier
depth gauge.
• Check the squareness with try square
• Finish by draw filing and deburr.

58 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.19

TASK21: Steps in thin sheet metal Fig 1

• Check the raw material size using steel rule (Fig 1).

Marking
• Mark the steps with vernier height gauge as per
drawing.

Sawing and filing the first step - Fig 2

• Cut and separate the excess material by sawing.
• File the step with safe edge file using bastard,
second cut and smooth grades maintaining the
accuracy of ± 0.5 mm.
Fig 2
• Measure the job sizes with vernier calliper and
vernier depth gauge.
• Check the squareness with square

Sawing and filing the second step - Fig 3

• Similarly, cut and separate the excess material by
sawing.
• File step with safe edge file using different grades
maintaining the accuracy of ± 0.5 mm.
• Measure the job size with vernier calliper and vernier
depth gauge.
Fig 3
• Check the squareness with try square
• Finish by draw filing and deburr.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.19 59

Production & Manufacturing Exercise 1.2.20
Aeronautical Structure & Equipment Fitter – Basic fitting operations

Filing chamfers to accuracy of ±0.5 mm

Objectives: At the end of this exercise you shall be able
• Filing chamfer.
• Tracing with vernier height gauge and protractor.
• Check dimension with bevel protractor.

TASK 1

1 60 x 60 x 10 A2017 - TASK-1 1.2.20

[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 4 Hrs

FILING CHAMFERS WITH AN ACCURACY OF +/-0.5
CODE NO.

60 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.20

 TASK 2

1 73 x 73 x 1.5 > 1.2.18 A2024 - TASK-2 1.2.20

[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 4 Hrs

FILING CHAMFERS WITH AN ACCURACY OF +/-0.5
CODE NO.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.20 61

Job Sequence

TASK 1: Make chamfer in thick part

• Check the raw material size using steel rule. Fig 1

File references
• File flat and straight by draw filing the 4 surfaces.
• Check flatness and squareness.
• Deburr edges.

Filing chamfer on angle

• Mark the two chamfers of 10x10 with vernier height
gauge and protractor. (Fig 1)
• File the chamfer using bastard, second cut and
smooth grades maintaining the accuracy of ±0.5
mm.
• Measure the job sizes with vernier calliper and bevel Fig 2
protractor.
• Finish by draw filing and deburr.
• Check the squareness with square.

Filing chamfer on long edge

• Mark the chamfer of 18 mm x10° with vernier height
gauge and protractor. (Fig 2)

NOTE: To facilitate tracing, calculate the value "a" using

trigonometric calculation or the Pythagorean theorem.

• File the chamfer using bastard, second cut and

smooth grades maintaining the accuracy of ±0.5
mm.
• Measure the job sizes with vernier calliper and bevel
protractor.
• Finish by draw filing and deburr.
• Check the squareness with square.

62 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.20

TASK 2: Make chamfer in thin sheet metal part Fig 1

• Check the raw material size using steel rule (Fig 1).

Tracing and filing chamfers

• Mark the two chamfers of 10x10 with vernier height
gauge and protractor.
• Mark the chamfers of 15x15 with vernier height
gauge and protractor.
• Mark the chamfers of 15x150° with vernier height
gauge and protractor.
• File the chamfers using bastard, second cut and
smooth grades maintaining the accuracy of ±0.5
mm.
• Measure the job sizes with vernier calliper and bevel
protractor.
• Finish by draw filing and deburr.
• Check the squareness with square.

Skill Sequence

Clamping the workpiece in the bench vice to chamfering

Objectives: This shall help you to
• Clamp a workpiece in good position to make a chamfer.

Set the correct position of the workpiece. Fig 1

• Hold the workpiece in the bench vice with a

minimum projection from the top of the vice jaw
without touching the vice.
• The workpiece must be in the centre of the jaws.
• Hold the workpiece with the chamfer angle to
facilitate the flat filing. (Fig 1)
• Close the jaws of the bench vice to tighten the
workpiece lightly by turning the handle in clockwise
direction.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.20 63

 Filing a chamfer
Objectives: This shall help you to
• File a chamfer.

During filing, the parallel position must be ensured. Indeed, if the shape is a trapezoid, it means that the
adjustment is inclined. (Fig 2)
It is possible to check visually by looking at the filed face
to ensure that it is a perfect rectangle. (Fig 1)
Fig 1 Fig 2

64 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.20

Production & Manufacturing Exercise 1.2.21
Aeronautical Structure & Equipment Fitter – Basic fitting operations

Filing convex radii

Objectives: At the end of this exercise you shall be able
• Filing radius.
• Tracing with vernier height gauge and fillet gauge.
• Check radius with fillet gauge.

TASK 1

1 60 x 60 x 10 A2017 - TASK-1 1.2.21

[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 4 Hrs

FILING CONVEX RADII
CODE NO.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.21 65

 TASK 2

1 73 x 73 x 1.5 > 1.2.18 A2024 - TASK-2 1.2.21

[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 4 Hrs

FILING CONVEX RADII
CODE NO.

66 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.21

Job Sequence

TASK 1: Make radii on thick part

• Check the raw material size using steel rule. Fig 1

File references
• File flat and straight by draw filing the 4 surfaces.
• Check flatness and squareness.
• Deburr edges.

Filing radii on angle

• Mark the two radii of R10 with vernier height gauge
and divider. (Fig 1)
• File the radii using bastard, second cut and smooth
grades maintaining the accuracy of ±0.5 mm.
• Measure the job sizes with fillet gauge.
Fig 2
• Finish by draw filing and deburr.

Filing radius on long edge

• Mark the limits of the radius with vernier height
gauge. (Fig 2)

NOTE: To facilitate filing, you can calculate the value "a"

of the first chamfer using trigonometric calculation or the
Pythagorean theorem. (Fig 3)

• File the radius using bastard, second cut and

smooth grades maintaining the accuracy of ±0.5
mm. Fig 3

• Measure the job sizes with fillet gauge.

• Finish by draw filing and deburr.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.21 67

TASK 2: Make radii on thin sheet metal Fig 1

• Check the raw material size using steel rule (Fig 1).

Filing radii on angle

• Mark the two radii of R10 with vernier height gauge
and divider.
• Mark the two radii of R15 with vernier height gauge
and divider.
• File the radii using bastard, second cut and smooth
grades maintaining the accuracy of ±0.5 mm.
• Measure the job sizes with fillet gauge.
• Finish by draw filing and deburr.

Skill Sequence

Punch centre to use divider

Objectives: This shall help you to
• Punch a dot mark using a dot punch

Place the sheet on the anvil stake. Hold the punch Fig 1
between the thumb and the first two fingers of the hand
where possible, rest the little finger and the edge of your
hand on the marked centre point as shown in Fig 1.
Fig 1

Bring up the dot punch in the vertical position and strike This dot punch marks prevent the divider leg from
with a ball peen hammer on the head of the dot punch slipping while scribing curved lines from the centre point.
lightly. Only a small dot is needed to prevent the divider from
Watch the point of the punch and strike its head with the slipping. If the dot is too big, compass leg will wander.
hammer Fig 2.

68 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.21

 Marking with divider
Objectives: This shall help you to
• Draw circles and arcs with a divider.

Verify that the legs of the divider are of the same length. Fig 3
(Fig 1)
If not, grind the leg and sharpen with an oilstone.
Fig 1

Punch at the intersection of the marked lines.

Only a small dot is needed to prevent the compass
from slipping.
Change the thumb position on the compass and draw
the rest of the circle from the lower left. (Fig 4)
While adjusting the compass opening, use the middle of
the rule and not the edge. Fig 4

For larger lengths, place the rule on the worktable and

adjust the divider opening, with both tips on the rule.
(Fig 2)
Fig 2

After setting the dimensions, lock the legs and check the When the drawing, tilt the compass slightly in the
dimensions again. direction of rotation.

Hold the compass head with the palm of your hand to

prevent the compass point from slipping from the centre
of the circle.
Draw an upper half circle from the lower left to the right,
using thumb pressure. (Fig 3)

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.21 69

 Filing a radius
Objectives: This shall help you to
• File a radius.

Set the workpiece in the vice as shown in Figure 1. Fig 3

Fig 1

File a chamfer until it is tangential to the radius line.

Check the shape (rectangular or trapezoidal) to ensure Repeat the operation on the other tip. (Fig 4)
parallel filing. (Fig 2)
Fig 4

Fig 2

Depending on the size of the radius, repeat the operation

until the chamfers are as small as possible.
Finish by draw filing.
Rotate the part to place a tip upwards and file a chamfer.
(Fig 3) Check with fillet gauge.
The filing must come tangent to the line.

70 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.21

Production & Manufacturing Exercise 1.2.22
Aeronautical Structure & Equipment Fitter – Basic fitting operations

Drilling with drill press

Objectives: At the end of this exercise you shall be able
• Set the drill bit in drill press chuck
• Calculate de cutting speed.
• Drill holes with drill press.

TASK 1

1 > 1.2.17 A2017 - TASK-1 1.2.21

[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 4 Hrs

DRILLING WITH DRILL PRESS
CODE NO.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.22 71

 TASK 2

1 73 x 73 x 1.5 > 1.2.18 A2024 - TASK-2 1.2.21

[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 4 Hrs

DRILLING WITH DRILL PRESS
CODE NO.

72 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.22

Job Sequence

TASK 1: Drilling thick part

• Check the raw material.
• Trace the lines.
• Punch the centre of the holes.
• Position and hold the workpiece in the vice in
position.
• Calculate the drilling speed and adjust the drill press.
• Drill all the holes at 3 mm.
• Counter-drill to the final diameter.
• Deburr both side with 90° countersinking cutter.

TASK 2: Drilling thin sheet metal Fig 1

• Check the raw material. (Fig 1)

• Trace the lines.
• Punch the centre of the holes.
• Position and hold the workpiece with clamps in
position.
• Drill all the holes at 3 mm.
• Counter-drill to the final diameter.
• Deburr both side with 90° countersinking cutter.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.22 73

Skill Sequence

Holding devices
Objectives: This shall help you to
• Identify and use the different holding devices.

Workpieces to be drilled should be properly held or Clamps and bolts

clamped to prevent from rotating along with the drill.
Drilling machine tables are provided with T-Slots for
Improperly secured work is not only a danger to the fitting bolt heads. Using clamps and bolts, the workpiece
operator but can also cause inaccurate work, and can be held very rigidly. (Fig 3)
breakage to the drill. Various devices are used to ensure
Fig 3
proper holding.

The machine vice

Most of the drilling work can be held in a machine vice.
Ensure that the drill does not drill through the vice after
it has passed through the work. For this purpose, the
workpiece can be lifted and secured on parallel blocks
providing a gap between the work and the bottom of the
vice. (Fig.1)
Fig 1

Use a Sacrificial Board

A sacrificial board is a flat piece of wood that you place
under something you're drilling. You drill through it when
making the hole.
When drilling thin sheet metal, clamp the metal over a
piece of sacrificial board (flat sheet good, like MDF or
particleboard) to help to prevent the bit from tearing up
the hole.

Fig 2

74 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.22

Production & Manufacturing Exercise 1.2.23
Aeronautical Structure & Equipment Fitter – Basic fitting operations

Make sheet metal with flanged holes

Objectives: At the end of this exercise you shall be able
• File notches in thin sheet metal.
• Prepare and make flanged holes.

1 100x200x2 A2024 - TASK-1 1.2.23

[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 12 Hrs

MAKE SHEET METAL WITH FLANGED HOLES
CODE NO.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.23 75

Job Sequence

• Check the raw material with steel rule. Fig 2

• File the four surfaces to give dimension to an

accuracy of ±0.2 mm.
• Finishing by draw filing.
• Deburr and check.
Chamfers
• Mark the chamfers and file them. (Fig 1)
• Finish by draw filing and deburr.
• Check dimension and angle.
Notches
• Mark the notches and the centre of the internal radii.
(Fig 2)
• Mark the external radii.
• Punch and drill to make the internal radii. Fig 3
• Saw along the marking line.
• File the notches.
• File the external radii.
• Finish by draw filing and deburr.
Flanged holes
• Make the centre of the flanged holes.
• Drill the centre and make lightening flanged holes
with press.
• File and deburr the lightening flanged holes.
• Check dimensions.

Fig 1
Fig 4

76 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.23

Production & Manufacturing Exercise 1.2.24
Aeronautical Structure & Equipment Fitter – Basic fitting operations

Make countersink, counterbore and spot face

Objectives: At the end of this exercise you shall be able
• Countersink hole.
• Counterbore hole.
• Spot face surface.

1 > 1.2.20 A2017 - TASK-1 1.2.24

[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 12 Hrs

MAKE COUNTERSINK, COUNTERBORE AND SPOT FACE
CODE NO.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.24 77

Job Sequence

Tracing and drilling

• In the flat face (Fig 1), mark the holes positions. Fig 2
• Punch the centre.
• Hold the workpiece and drill holes to diameter 4.
• Deburr both sides.
Countersink (Fig 2)
• Hold the workpiece on machine vice.
• Set the countersinking depth by successive tests.
• Check dimension and depth.
TABLE 1
d1 d2 t1
Fig 3
…. …. ….

Counterboring (Fig 3)
• Hold the workpiece on machine vice.
• Set the counterboring depth by successive tests and
check with depth gauge.
• Check dimension and depth.
TABLE 2
d1 d2 t1
…. …. 3 mm
Fig 4

Spot facing (Fig 4)

• Hold the workpiece on machine vice.
• Spot face in a successive pass to obtain a flat
surface finishing flush with the chamfer.
TABLE 3
d1 d2
…. ….

Fig 1

78 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.24

Production & Manufacturing Exercise 1.2.25
Aeronautical Structure & Equipment Fitter – Basic fitting operations

Make internal thread

Objectives: At the end of this exercise you shall be able
• Threading hole.
• Check internal threads.

1 > 1.2.21 A2017 - TASK-1 1.2.25

[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 12 Hrs

MAKE INTERNAL THREAD
CODE NO.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.25 79

Job Sequence

Tracing and pre-drilling TABLE 1

• Mark the holes positions. Thread Drilling diameter

• Punch the centre. M4

• Hold the workpiece and drill holes to diameter 3. M6

• Deburr both sides. M8

Drilling final diameter (Table 1) Threading

• Hold the workpiece on machine vice. • Select the correct taps set.

• Drill to the final diameter according to table 1. • Tap the holes.

• Chamfering both sides. • Check threading with gauge or bolt.

Skill Sequence

Tapping through holes

Objectives: This shall help you to
• Cut internal threads using hand taps.

Determine the tap drill size either using the formula or Hold the work firmly and horizontally in the vice. The top
the table. surface of the job should be slightly above the level of
the vice jaws. This will help in using a square without any
Drill the hole to the required tap drill size.
obstruction while aligning the tap. (Fig 2)
An undersized hole will lead to breakage of the tap.
Chamfer the end of the drilled hole for easy aligning and Fig 2
starting of the tap. (Fig 1)
Fig 1

80 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.25

Fix the first tap (taper tap) in the correct size tap wrench. positioned vertically. The wrench pressure exerted by
the hands should be well balanced. Any extra pressure
Position the tap in the chamfered hole vertically by
on one side will spoil the tap alignment and can also
ensuring the wrench is in a horizontal plane.
cause breakage of the tap. (Fig 5).
Exert steady downward pressure and turn the tap Fig 5
wrench slowly in the clockwise direction to start the
thread. Hold the tap wrench close to the centre. (Fig 3)
Fig 3

Continue cutting the thread. Turn backwards frequently

about quarter turn, to break the chips. (Fig 7)
Fig 6

Remove the wrench from the tap when you are sure of
starting the thread without disturbing the setting.

Check and make sure that the tap is vertical by using a

square in two positions at 90° to each other. (Figs 4)
Fig 4

Stop and turn backwards when any obstruction to the

movements is felt.
Use a cutting fluid while cutting the thread to minimise
friction and heat.

Cut the thread until the hole is totally threaded.

Remove the chips from the work and clean the tap with
a brush.

Make sure that the diameter of the hole to be tapped

is correct for the given size of the tap.
If necessary, make correction by exerting slightly more Turn backwards to break the chip after every quarter
pressure on the opposite side of the tap inclination. turn.
Check the tap alignment again. The tap alignment Select the length of wrench suitable to the size of the
should be corrected within the first few turns. If it is tried tap. Overlength of wrench may cause the breakage
afterwards there is a possibility of breaking of the tap. of tap.
Turn the wrench lightly by holding at the ends without
exerting any downward pressure after the tap is

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.25 81

Production & Manufacturing Exercise 1.2.26
Aeronautical Structure & Equipment Fitter – Basic fitting operations

Ream holes with hand reamer

Objectives: At the end of this exercise you shall be able
• Hand reaming.
• Check reamed hole with go-no go gauge.

1 40X100 – 2 mm A7075 - TASK-1 1.2.26

1 40X100 – 2 mm STAINLESS STEEL - TASK 2 1.2.26
1 40X100 – 5 mm A2017 - TASK 3 1.2.26
1 40X100 – 5 mm STEEL - TASK 4 1.2.26
[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 12 Hrs

REAM HOLES WITH HAND REAMER
CODE NO.

82 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.26

Job Sequence

TASK 1 – Aluminium 7075 TASK 3 – Aluminium 2017

• Check dimensions and thickness. • Check dimensions and thickness.
• Mark and file external dimension and radii. • Mark and file external dimension and radii.
• Mark the holes positions. • Mark the holes positions.
• Punch the centre. • Punch the centre.
• Hold the workpiece and drill holes. • Hold the workpiece and drill holes.
• Determine the diameter before reaming. • Determine the diameter before reaming.
• Deburr both sides. • Deburr both sides.
• Ream the holes. • Ream the holes.
• Check diameter. • Check diameter.

TASK 2 – Stainless steel TASK 4 – Steel

• Check dimensions and thickness. • Check dimensions and thickness.
• Mark and file external dimension and radii. • Mark and file external dimension and radii.
• Mark the holes positions. • Mark the holes positions.
• Punch the centre. • Punch the centre.
• Hold the workpiece and drill holes. • Hold the workpiece and drill holes.
• Determine the diameter before reaming. • Determine the diameter before reaming.
• Deburr both sides. • Deburr both sides.
• Ream the holes. • Ream the holes.
• Check diameter. • Check diameter.

TABLE 1: General tolerances

External dimensions and radius ± 0.2 mm

Holes positions ± 0.1 mm

TABLE 2: Dimensions and material by task

TASK MATERIAL THICKNESS HOLE DIAMETER

TASK 1 A7075 5 mm Ø6H8
TASK 2 STAINLESS STEEL 5 mm Ø6H8
TASK 3 A2017 5 mm Ø6H8
TASK 4 STEEL 5 mm Ø6H8

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.26 83

Skill Sequence

Reaming drilled holes using hand reamers

Objectives: This shall help you to
• Ream through holes

Determining the drill size for reaming Fig 2

Determine the tap drill size either using the table 1.

TABLE 1
Undersize for reaming

Diameter of ready Undersize of rough

reamed hole (mm) bored hole (mm)
Under 5 0.1 / 0.2
5 to 20 0.2 / 0.3
21 to 50 0.3 / 0.5
Over 50 0.5 / 1.0

Hand reaming Ream the hole through. Ensure that the taper lead length
Chamfer the hole ends slightly. This removes burrs, and of the reamer comes out well and clear from the bottom
of the workpiece. Do not allow the end of the reamer to
will also help to align the reamer vertically (Fig 1). Fix the strike on the vice.
workpiece in the bench vice. Ensure that the workpiece
is horizontal. Remove the reamer with an upward pull until the reamer
is clear of the hole. (Fig 3)
Fig 1
Fig 3

Fix the tap wrench on the square end and place the
reamer vertically in the hole. Check the alignment with a
square. Make corrections, if necessary. Turn the tap
wrench in a clockwise direction applying a slight
downward pressure at the same time (Fig 2). Apply
pressure evenly at both ends of the tap wrench. Remove the burrs from the bottom of the reamed hole.
Apply cutting fluid. Clean the hole. Check the accuracy with the go-no go
Turn the tap wrench steadily and slowly, maintaining the gauge.
downward pressure.

Do not turn in the reverse direction it will scratch the

reamed hole.

84 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.26

Production & Manufacturing Exercise 1.2.27
Aeronautical Structure & Equipment Fitter – Basic fitting operations

Make components to assembly

Objectives: At the end of this exercise you shall be able
• File components as per required tolerance.

1 100x160 – 10 mm A2024 - TASK 1 1.2.27

[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 6 Hrs

MAKE COMPONENTS TO ASSEMBLY
CODE NO.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.27 85

 Quantity: 2

2 100x60 – 5 mm A2024 - TASK 2 1.2.27

[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 12 Hrs

MAKE COMPONENTS TO ASSEMBLY
CODE NO.

86 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.27

 Quantity: 2

2 ROD Ø 6h10 – 42 mm Constructional steel - TASK 3 1.2.27

[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 1 Hr

MAKE COMPONENTS TO ASSEMBLY
CODE NO.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.27 87

Job Sequence

TASK 1 – Component 1 • File external dimensions and finish by draw filing.

• Check dimensions and thickness. • Check flatness, squareness and sizes.
• File external dimensions and finish by draw filing. • Mark lines as per drawing and punch on the drill hole
using centre punch.
• Check flatness, squareness and sizes.
• Punch the centre of the holes.
• Mark lines as per drawing and punch on the drill hole
using centre punch. • Hold in machine vice and drill.
• Hold in drilling machine. • Drill 2 holes to make internal radii.
• Determine the drill size for reaming and threading. • Drill 5 holes (diameter 6.2).
• Drill the holes. • Saw internal notch and file.
• Deburr and chamfer. • Deburr and chamfer.
• Ream the 4 holes (Ø6H8).
• Thread the 10 hole (M6). TASK 3 – Component 3
• Check with go-no go gauge and thread gauge. • Check dimensions.
• Mark, saw and file external dimension.
• Deburr by chamfering both tips.
TASK 2 – Component 2
• Check dimensions and thickness.

TABLE 1: General tolerances

External dimensions ± 0.2 mm

Notch and radius ± 0.2 mm

Holes positions ± 0.1 mm

TABLE 2: Dimensions and material by task

TASK MATERIAL THICKNESS

TASK 1 A2024 10 mm
TASK 2 A2024 5 mm
TASK 3 STEEL Diameter 6 mm

88 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.27

Production & Manufacturing Exercise 1.2.28
Aeronautical Structure & Equipment Fitter – Basic fitting operations

Make assembly with interchangeability

Objectives: At the end of this exercise you shall be able
• Assemble components with interchangeability.

1 > 1.2.27 TASK 1 - 1.2.28

2 > 1.2.27 TASK 2
2 > 1.2.27 TASK 3
4 > 1.2.26
[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 6 Hrs

MAKE ASSEMBLY
CODE NO.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.27 89

 2 100x60 – 5 mm A2024 - TASK 2 1.2.27
[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 12 Hrs

MAKE ASSEMBLY – POSITION 1
CODE NO.

90 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.27

 2 ROD Ø 6h10 – 42 mm Constructional steel - TASK 3 1.2.27
[Link] STOCK SIZE SEMI-PRODUCT MATERIAL PROJECT NO. PART NO. EX. NO

SCALE: NTS DEVIATIONS TIME 1 Hr

MAKE ASSEMBLY – POSITION 2
CODE NO.

Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.27 91

Job Sequence

TASK 1 – Assembling TASK 2 – Interchangeability

• Assemble with hexagonal bolts the 2 parts make in • Put in position 1 the component A-Exercise 1.2.26
task 2 – exercise 1.2.27. with pins (see table 1).
• Check assembly. • Check position and gap and report on table.
• Make the same work with the other 3 components B,
C and D-Exercise 1.2.26 (see table 1).

TABLE 1

POSITION 1 POSITION 2
COMPONENT MATERIAL
Position Regular gap Position Regular gap

o OK o NOK o OK o NOK o OK o NOK o OK o NOK

A A7075 NOTES NOTES

o OK o NOK o OK o NOK o OK o NOK o OK o NOK

B STAINLESS STEEL NOTES NOTES

o OK o NOK o OK o NOK o OK o NOK o OK o NOK

C A2017 NOTES NOTES

o OK o NOK o OK o NOK o OK o NOK o OK o NOK

D STEEL NOTES NOTES

92 Fabrication: Aeronautical Structure and Equipment Fitter – Exercise 1.2.27