Countersink hole with drill bit on one side. ⅜" File both pieces to remove any burrs after drilling. Assembly of letter opener Place a rivet set in the vise. Place a rivet through the hilt topper and letter opener. ⅛" Position the rivet head into the corresponding hole on the rivet set anvil. Use a ball peen hammer to mushroom the rivet. Hammer the rivet flat against the letter opener back. File any excess material from the rivet to make it smooth against the hilt. Finishing Clean any grease, dirt, or scratches in the metal using emery cloth. Choose an appropriate method of finishing (painting, powder coating, etc.). Assessment Consider co-creating the assessment criteria with your students at the beginning of the activity/ project. You may want to include the following: Shield size is within to of the template size overall ⅛" 1⁄16" Dome is evenly hammered out Outside edge of dome is within of a 3" circle 1⁄16" Shield riveting is flat and smooth Letter opener length is within 1⁄16" Handle riveting is flat and smooth to handle Hilt is within of length 1⁄16" Finishing: all edges are smooth
Countersink hole with ⅜" drill bit on one side. File both pieces to remove any burrs after drilling. Assembly of letter opener Place a rivet set in the vise. Place a ⅛" rivet through the hilt topper and letter opener. Position the rivet head into the corresponding hole on the rivet set anvil. Use a ball peen hammer to mushroom the rivet. Hammer the rivet flat against the letter opener back. File any excess material from the rivet to make it smooth against the hilt. Finishing Clean any grease, dirt, or scratches in the metal using emery cloth. Choose an appropriate method of finishing (painting, powder coating, etc.). Assessment Consider co-creating the assessment criteria with your students at the beginning of the activity/ project. You may want to include the following: Shield size is within 1⁄16" to ⅛" of the template size overall Dome is evenly hammered out Outside edge of dome is within 1⁄16" of a 3" circle Shield riveting is flat and smooth Letter opener length is within 1⁄16" Handle riveting is flat and smooth to handle Hilt is within 1⁄16" of length Finishing: all edges are smooth