I need cool, simple metal working projects for high school students

[harryn]

We used to make an open metal tool box as our first sheet metal project, but we had access to a pretty good size brake.

Probably the lowest capital cost projects would be to make some kind of stick figures out of copper tubing - just cut and solder them together with an even decent torch.

If you get a torch hot enough to weld, you can make up a tube frame for a go cart - that would be pretty cool.

I know this sounds simplistic, but my 10 year old and I have made lots of stuff from PVC pipe.

Interestingly, you might have more luck obtaining a used industrial lathe for cheap than a hobby style. There aren't that many homes that can take them (power / space / weight) and you can be sure that having a bunch of users, you will need the durability.

[lylekelley3]

How about musical instrments.

Everthing from a simple rattle to a simplified string instrument. Your CNC router should be able to cut the pieces, then it's glue, clamp, trim and finish.
A gogle search for plans should be fruitful.

Lyle

[TerryFehr]

2 years ago when I was in grade 9 we made dominoes. It was our introduction to hand tools. We had some flat iron that we had to cut out (approx. 2"by1") then we had to measure out half and file a line through the middle. Then we took a drill and drilled holes just like a real domino.

[Joe S.]

Giving your lack of equipment, and the kids are still pretty young, you could have them make simple items as gifts for their parents. One that occur ed to me was simple key chains. the chains could be made from narrow slices of copper tubing where every other link is split and soldered together, or make from sheet brass or brazing rod, and solder every link. Teaches light metal working and soldering skills, use lead free solder. Have the whole class design a wire loop bender and build it, so they can make the chain loops, by sawing the loops from the coil. Jeweler's saws are relatively cheap. Those skills could be taken in several different directions later on.
Another simple project is a hand built electric (battery) motor.
Another idea: have them fashion up some small wind turbines to attach to a stepper motor and wire it to work as a generator to charge small batteries or light LEDs.

[pl_tech]

I use to teach a metal working unit where we made tools such as setting hammers. The basic tools you will need is a hacksaw, a drill, files.

We made the hammer head out of 3/4" square stock and cut it 3-4" long. The student had to cut the angle of the setting hammer (make sure to save the angle drop piece). Once the angle was cut we used files to flatten the rough cut. Our poor man's mill (file) would true up the stock as well and chamfer the ends. We then drilled a hole for the wooden handle. We had to use a round file to clean out the overlapping drilled holes. I believe the slot was 3/8" by 3/4" through the stock. The wooden handle was made out of hardwood that I found off of pallets. The student had to crosscut the stock to length as well as saw the taper handle. Of course we used a file to make the handle too. We cut a slot in the end of the handle and then used the drop off wedge piece to secure the hammer head into place. We used tung oil to finish the handle. Many of my former students who see me tell me that they still have those items they made so many years ago.

You can find plans just about anywhere, just look in old Popular mechanics and popular science magazines. You can search Google books and locate plans through their search engine. Some where I have those plans and I should dig them up.

I am currently teaching and engineering graphics course and we just purchased a jet lathe and a jet mill. I plan to teach them how to design tools as well as how to machine their prototype.