Metalwork Merit Badge
CLASS PREPARATION PAGE
 
GENERAL INSTRUCTIONS
 
Please arrive with ample time prior to the start time of your class for registration.  Remember there will be others checking in as well and depending on the size of the class, and the event the class is being held in conjunction with, that registration may take a little time.

You should bring a blue card filled out properly for this class. - Scoutmaster Bucky Online participants - you will not be allowed to participate if you have not provided your signed blue card prior to the class - you should have forwarded your blue card to Scoutmaster Bucky prior to the class via email or postal mail:
Scoutmaster Bucky - 5724 Aldrich Avenue South  Minneapolis, Minnesota  55419.

If you are not familiar with how to fill out a blue card, you should familiarize yourself with Scoutmaster Bucky's "How To Fill Out A Blue Card" document. Click here for Scoutmaster Bucky's "How To Fill Out A Blue Card".  Remember it is a Scout's responsibility to take care of their own blue card from beginning to end.
 
 
 
Your Scout Uniform is required to be worn for attending this Merit Badge session.   If you have any additional questions, please feel free to contact Brian Reiners; Scoutmaster Bucky via email or on the phone at 612-483-0665.

Reviewing the merit badge pamphlet PRIOR to attending and doing preparation work will insure that Scouts get the most out of these class opportunities. The merit badge pamphlet is a wealth of information that can make earning a merit badge a lot easier. It contains many of the answers and solutions needed or can at least provide direction as to where one can find the answers.

It is NOT acceptable to come unprepared to a Scoutmaster Bucky event. You can (and should) use the Scoutmaster Bucky Metalwork Merit Badge Workbook to help get a head start and organize your preparation work. Please note that the use of any workbook is merely for note taking and reference and completion of any Merit Badge workbook does not warrant, guarantee, or confirm a Scouts completion of any merit badge requirement(s). You can download the Scoutmaster Bucky Metalwork Merit Badge Workbook by clicking here .   If this link is not working please check the internet for other merit badge workbook options.

It should be noted that this merit badge class is not meant for those who just want to come and see what they can get done. It is possible to complete this merit badge by being properly prepared and having done the preparation work prior to the class. Preparation is a MUST 
 
 
Other Metalwork MERIT BADGE PAGES
 
Metalwork Merit Badge Current Requirements
 
Scoutmaster Bucky's - Metalwork Merit Badge Workbook
 
Metalwork Merit Badge and Merit Badge History Page
 
Metalwork MERIT BADGE SPECIFICS
 

Metalwork Merit Badge Things to remember to bring for this Merit Badge Class:

1. Merit Badge Blue Card properly filled out and signed off by your Scoutmaster

2. Metalwork Merit Badge Pamphlet

3. Scout Uniform

4. Footwear should be work boots or protective type footwear; no open toed shoes allowed.

5.Scouts should bring a change of clothing that they don't mind getting dirty as some class work may get a little messy. Work gloves are also recommended if you have them.

6. Supporting documentation or project work pertinent to this merit badge which may also include a Merit Badge Workbook for reference with notes

7. A positive Scouting focus and attitude

 
REQUIREMENTS WITH SUGGESTED STUDY PREPARATION NOTES

IT MUST BE NOTED THAT DUE TO THE SAFETY LEVEL REQUIRED FOR THIS MERIT BADGE CLASS, SCOUTS NOT FOLLOWING DIRECTION OR FAILING TO ADHERE TO CLASS INSTRUCTIONS MAY BE REMOVED FROM THE CLASS AND FORFEIT PARTICIPATION FEES AND PRIVILEGE OF CONTINUING TO PARTICIPATE. PARENT OR GUARDIAN WILL BE ASKED TO COME AND REMOVE SCOUT FROM THE EVENT.

 

1. Read the safety rules for metalwork. Discuss how to be safe while working with metal. Discuss with your counselor the additional safety rules that apply to the metalwork option you choose for requirement 5.

Scouts should review this requirement and its components and be prepared to discuss, demonstrate, explain, and show as necessary their recognition of potential hazards and first aid knowledge and proficiency as it applies to this merit badge.  Understanding of safety rules as it pertains to the metal-discipline selected will be vital and required for any Scout to participate in the class. Arriving without preparation of this requirement may negate the Scout from further participation in the class for safety reasons. Participation, as well as completion of this requirement, are at the sole discretion of the merit badge counselor and/or instructor and is not negotiable. Be prepared.

 

2. Define the terms native metal, malleable, metallurgy, alloy, nonferrous, and ferrous. Then do the following:

Scouts will find the use of a notebook or merit badge workbook to be helpful in completing the first part of this requirement. Scouts should be familiar and understand the terms listed above and be prepared to share their knowledge and understanding of these terms with the counselor during the class.

a. Name two nonferrous alloys used by pre-Iron Age metalworkers. Name the metals that are combined to form these alloys.

b. Name three ferrous alloys used by modern metalworkers.

c. Describe how to work-harden a metal.

d. Describe how to anneal a nonferrous and a ferrous metal.

Components 2a thru 2d are necessary terms, processes, and practices that Scouts must understand in order to successfully participate in the activity requirements of this merit badge. Scouts will find the Metalwork Merit Badge pamphlet to be a reliable source to reference for preparation on these components. Scouts should be prepared for discussion and presentation of their knowledge and findings with the counselor in the class.

 

3. Do the following:

a. Work-harden a piece of 26- or 28-gauge sheet brass or sheet copper. Put a 45-degree bend in the metal, then heavily peen the area along the bend line to work-harden it. Note the amount of effort that is required to overcome the yield point in this unworked piece of metal.

b. Soften the work-hardened piece from requirement 3a by annealing it, and then try to remove the 45-degree bend. Note the amount of effort that is required to overcome the yield point.

c. Make a temper color index from a flat piece of steel. Using hand tools, make and temper a center punch of medium-carbon or high-carbon steel.

c. Make a temper color index from a flat piece of steel. Using hand tools, make and temper a center punch of medium-carbon or high-carbon steel.

This requirement will be done as a part of the class.

 

4. Find out about three career opportunities in metalworking. Pick one and find out the education, training, and experience required for this profession. Discuss this with your counselor, and explain why this profession might interest you.

Scouts should review this requirement and its components and be prepared to discuss. It is strongly recommended that Scouts bring any notes or supporting documents they may have to help show the counselor that they have prepared for completion of this requirement.

 

5. After completing the first four requirements, complete at least ONE of the options listed below.

This requirement will be done in the class; the selected option will be determined by the counselor and resources available.  Any Metalwork class offered thru the Scoutmaster Bucky program will specify the selected option and be known when registering for the class.  It should be understood that the project work for this merit badge may exceed the time allotted during the class and most likely will require follow up work and review after the class to afford the opportunity for successful completion.

      a. Option 1 - Sheet Metal Mechanic/Tinsmith

(1) Name and describe the use of the basic sheet metalworking tools.

(2) Create a sketch of two objects to make from sheet metal. Include each component's dimensions on your sketch, which need not be to scale.

(3) Make two objects out of 24- or 26-gauge sheet metal. Use patterns either provided by your counselor or made by you and approved by your counselor. Construct these objects using a metal that is appropriate to the object's ultimate purpose, and using cutting, bending, edging, and either soldering or brazing.

(a) One object also must include at least one riveted component

(b) If you do not make your objects from zinc-plated sheet steel or tin-plated sheet steel, preserve your work from oxidation.

      b. Option 2 - Silversmith

(1) Name and describe the use of a silversmith's basic tools.

(2) Create a sketch of two objects to make from sheet silver. Include each component's dimensions on your sketch, which need not be to scale.

(3) Make two objects out of 18- or 20-gauge sheet copper. Use patterns either provided by your counselor or made by you and approved by your counselor. Both objects must include a soldered joint. If you have prior silversmithing experience, you may substitute sterling silver, nickel silver, or lead-free pewter.

(a) At least one object must include a sawed component you have made yourself.

(b) At least one object must include a sunken part you have made yourself.

(c) Clean and polish your objects.

      c. Option 3 - Founder

(1) Name and describe the use of the basic parts of a two-piece mold. Name at least three different types of molds.

(2) Create a sketch of two objects to cast in metal. Include each component's dimensions on your sketch, which need not be to scale.

(3) Make two molds, one using a pattern provided by your counselor and another one you have made yourself that has been approved by your counselor. Position the pouring gate and vents yourself. Do not use copyrighted materials as patterns.

(a) Using lead-free pewter, make a casting using a mold provided by your counselor.

(b) Using lead-free pewter, make a casting using the mold that you have made.

      d. Option 4 - Blacksmith

(1) Name and describe the use of a blacksmith's basic tools.

(2) Make a sketch of two objects to hot-forge. Include each components dimensions on your sketch, which need not be to scale.

(3) Using low-carbon steel at least 1/4-inch thick, perform the following exercises:

(a) Draw out by forging a taper.

(b) Use the horn of the anvil by forging a U-shaped bend.

(c) Form a decorative twist in a piece of square steel.

(d) Use the edge of the anvil to bend metal by forging an L-shaped bend.

(4) Using low-carbon steel at least 1/4-inch thick, make the two objects you sketched that require hot-forging. Be sure you have your counselor's approval before you begin.

(a) Include a decorative twist on one object.

(b) Include a hammer-riveted joint in one object.

(c) Preserve your work from oxidation.

 
this page last reviewed / updated: April 2019