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Shipyard Outside Machinist, Bulletin 345-K, 1942, was created during the peak of the massive shipbuilding campaign of WW II. During the war a large number of workers were trained in new trades to meet the increased demand for new labor. This was one of the courses created to prepare those new workers.

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Image of the the cover.
A suggested Unit Course
SHIPYARD
OUTSIDE MACHINIST
(For Beginning and Advanced Instruction)
Bulletin 345-K
Commonwealth of Pennsylvania
Department of Public Instruction
Harrisburg
1942

Vocational Training
for
War Production Workers

 

Boring a Stern Frame Rudder Gudgeon
Boring a Stern Frame Rudder Gudgeon
 


A suggested Unit Course
SHIPYARD
OUTSIDE MACHINIST
(For Beginning and Advanced Instruction)

Bulletin 345-K

Prepared by the
COMMONWEALTH OF PENNSYLVANIA
DEPARTMENT OF PUBLIC INSTRUCTION
DIVISION OF INDUSTRIAL EDUCATION

In Cooperation With

SUN SHIPBUILDING AND DRY DOCK COMPANY
CHESTER, PENNSYLVANIA

SCHOOL DISTRICT OF PHILADELPHIA

SCHOOL DISTRICT, CITY OF CHESTER

and

UNITED STATES OFFICE OF EDUCATION
FEDERAL SECURITY AGENCY

Commonwealth of Pennsylvania
DEPARTMENT OF PUBLIC INSTRUCTION
Harrisburg
1942

 

This Material Was Prepared
In Cooperation With The
United States Office of Education
The Federal Security Agency
Washington, D. C.
 

Forward

The rapid expansion of shipbuilding, with an accompanying increase in the number of shipyard outside machinists to be trained, has prompted the development and publication of this manual of instruction.

The procedures presented here are specifically those which are followed in the yard of the Sun Shipbuilding and Dry Dock Company. Persons who have developed this material realize that certain procedures may not be applicable to all types of shipyards.

Much of the information presented, however, is standard practice which will be useful in training shipyard outside machinists for most shipyards. Through the courtesy of the Alabama State Department of Education, certain items of instructional material have been selected from their training course for Shipyard Outside Machinists and adapted to fit local requirements.

Acknowledgment is made to the Sun Shipbuilding and Dry Dock Company, Chester, Pennsylvania, and to foremen, mechanics, and draftsmen employed by the Sun Yard for assistance and cooperation in making the preliminary analysis and in preparing instruction materials.

Special acknowledgment is extended to George Ehaugh, General Foreman of Installation Machinists; to William Evans, Foreman of Installation Machinists; and to E. G. Lamberson, Foreman of the Tube Mill. These men assisted materially in the preparation of text matter, sketches, and photographs; they served also in the capacity of technical advisers. The assistance of George Amrhein, E. L. Moritz, G. E. Marvel, J. W. Randall, James Galway, Joseph Kehl, and Ralph Garman, Leaders of Installation Machinists, is gratefully acknowledged.

Appreciation is extended to the Philadelphia School District; to the Chester School District; to D. Francis Hallowell, Coordinator of Chester Area Defense Training Program; and to William A. Brock, Area Coordinator of Industrial Education, for assistance in this work.

Acknowledgment is also extended to the Cramp Shipyard, Philadelphia, and to J. J. Campbell, Outside Machinist Instructor, Mastbaum Vocational School Annex, Philadelphia, for assistance in the preparation of suggested types of training jobs in correlation with instruction sheets contained in this manual.

This manual of instruction was prepared by the Chester Field Curriculum Laboratory of the Pennsylvania Department of Public Instruction, under the immediate supervision of Charles Johnston, Adviser, Division of Industrial Education. The work was completed under the direction of Charles F. Zinn, Adviser, Division of Industrial Education, and under the general supervision of Paul L. Cressman, Director, Bureau of Instruction, and Urwin Rowntree, Chief, Division of Industrial Education.

October, 1942 FRANCIS B. HAAS
Superintendent of Public Instruction
 

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Introduction

DUTIES OF A SHIPYARD OUTSIDE MACHINIST

Shipyard outside machinists are required to make certain installations, above and below deck, throughout the ship. The equipment to be installed is fabricated in various departments of the shipyard or purchased from approved manufacturers.

The work of the outside machinist may start when the hull begins to take shape, depending altogether on the circumstances which govern the fabrication of units built in the shipyard, the speed of hull construction, and the availability of purchased units. In some cases the work of the outside machinist is 75% completed before the ship leaves the ways. At other times the greater part of the work is not started until the ship is launched.

APPLICATION OF THE MANUAL

The manual Shipyard Outside Machinist may be applied to the training of the beginning workers, advanced workers, and maintenance and repair outside machinists. It is designed principally for the guidance of shipyard outside machinists, that is, those machinists whose work is done around the wet basins and on the ways. Many of the processes and operations presented are also applicable to shop machinist's training problems. This outline is specifically intended for training outside machinists (Marine); it is not intended for instruction of general shipyard shop machinists.

 

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CONTENTS

PART I
OUTSIDE MACHINIST TRAINING FOR BEGINNERS

INTRODUCTION
Safety 3
Location of Shops, Ways, etc., in the Yard 6
Tools and Equipment:
  (a) Tool Kit Owned by the Outside Machinist 7
  (b) Tool Crib: Tools Found in Tool Crib, Usually Company Owned 8
 
GENERAL ARRANGEMENT OF A SHIP
Plan and Elevation, Ship Terms, and Locations 9
 
CORRECT USE OF TOOLS AND
GENERAL WORK FOR THE NEW MAN
Mechanics' Scale and Steel Tape 12
Calipers, Dividers, and Hermaphrodites 23
Reading the Micrometer 28
Machinists' Hammer and Center Punch 36
Cold Chisels: Types and Uses 38
Open End Wrenches 40
Drills and Drilling 41
Reamers and Reaming 47
Reaming "Through" Holes 50
Using a Portable Air Drill with Ratchet and "Old Man" 55
Threading Bolts and Nuts (Tapping Holes) 60
Tightening a Stud in a Threaded Hole 65
Removing Studs or Broken Bolts 67
Screw Driver 69
Files 70
Fitting a Key 74
General Discussion of Other Outside Machinists' Tools Listed in Part I 75
 
PART II
OUTSIDE MACHINIST TRAINING
ADVANCED WORK AND MAINTENANCE
Using a Portable Grinder 91
Fitting Chocks 92
Using Gasket Material and Thread Dope 97
Making a Full Face Gasket 100
Making a Ring Gasket for a Standard Six-inch Flange Joint 101
Cutting a Dovetail Gasket 102
Making and Installing a Grommet 104
Packing a Stuffing Box 105
Making a Watertight Joint 108
 

Overhauling a Valve 109
Grinding Valve Seats 113
Setting a Valve 117
Using a Declivity Board and Level. 119
Striking a Chalk Line 122
Setting and Fitting a Deck Stand 125
Installing a Pump 128
Lining Up Pumps and Motors 130
Aligning a Coupling 132
Overhauling a Pump 136
Spotting and Scraping Bearings 147
Installing Operating Rods 153
Fitting a Sea Chest Strainer Plate 158
Installing Main Suction Valve 161
Installing Overboard Spools 163
 
PART III
ADVANCED OUTSIDE MACHINIST TRAINING
INSTALLATIONS, MAINTENANCE, REPAIRS
Running a Tight Line 171
Removing a Tight Line 178
Setting a Portable Boring Bar 179
Boring a Stern Frame 184
"Pulling-In" a Stern Tube 188
Installing a Propulsion Motor 193
Installing Fan and Motor for Air Cooler 198
Installing a Steam Boiler 201
Installing Winches 209
Installing a Steering Gear, and Telemotor for Pilot House Indication 223
Installing a Propeller and Tail Shaft 246
Launching a Tanker 250
 
APPENDIX I
Typical Drawings that Outside Machinists Must be Able to Read 255
 
APPENDIX II
Shipyard Outside Machinist Terms and Definitions 279
 
APPENDIX III
Abbreviations Used by Shipbuilders 293
 
APPENDIX IV
Dimensions of Standard Iron and Steel Pipe 295
 
APPENDIX V
Using the Sag Table 296
Index 299

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