Merit Badge Workbook
This Scoutmaster Bucky Merit Badge Workbook is based off the 2020 Scouts BSA Requirements.
Requirement 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.
Requirement 2: Define the terms native metal, malleable, metallurgy, alloy, nonferrous, and ferrous. Then do the following:
Requirement 2a: Name two nonferrous alloys used by pre-Iron Age metalworkers. Name the metals that are combined to form these alloys.
Requirement 2b: Name three ferrous alloys used by modern metalworkers.
Requirement 2c: Describe how to work-harden a metal.
Requirement 2d: Describe how to anneal a nonferrous and a ferrous metal.
Requirement 3: Do the following:
Requirement 3a: 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.
Requirement 3b: 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.
Requirement 3c: 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.
Requirement 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.
Requirement 5: After completing the first four requirements, complete at least ONE of the options listed below.
(a) Option 1 – Sheet Metal Mechanic/Tinsmith
Requirement 3c1: Name and describe the use of the basic sheet metalworking tools.
Requirement 3c2: 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.
Requirement 3c3: 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.
Requirement 3c3a: One object also must include at least one riveted component.
Requirement 3c3b: 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
Requirement 3c1: Name and describe the use of a silversmith's basic tools.
Requirement 3c2: 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.
Requirement 3c3: 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.
Requirement 3c3a: At least one object must include a sawed component you have made yourself.
Requirement 3c3b: At least one object must include a sunken part you have made yourself.
Requirement 3c3c: Clean and polish your objects.
(c) Option 3 – Founder
Requirement 3c1: Name and describe the use of the basic parts of a two-piece mold. Name at least three different types of molds.
Requirement 3c2: Create a sketch of two objects to cast in metal. Include each component's dimensions on your sketch, which need not be to scale.
Requirement 3c3: 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.*
Requirement 3c3a: Using lead-free pewter, make a casting using a mold provided by your counselor.
Requirement 3c3b: Using lead-free pewter, make a casting using the mold that you have made.
(d) Option 4 – Blacksmith
Requirement 3c1: Name and describe the use of a blacksmith's basic tools.
Requirement 3c2: Make a sketch of two objects to hot-forge. Include each component’s dimensions on your sketch, which need not be to scale.
Requirement 3c3: Using low – carbon steel at least ¼ inch thick, perform the following exercises:
Requirement 3c3a: Draw out by forging a taper.
Requirement 3c3b: Use the horn of the anvil by forging a U-shaped bend.
Requirement 3c3c: Form a decorative twist in a piece of square steel.
Requirement 3c3d: Use the edge of the anvil to bend metal by forging an L-shaped bend.
Requirement 3c4: Using low-carbon steel at least ¼ inch thick, make the two objects you sketched that require hot-forging. Be sure you have your counselor's approval before you begin.
Requirement 3c4a: Include a decorative twist on one object.
Requirement 3c4b: Include a hammer-riveted joint in one object.
Requirement 3c4c: Preserve your work from oxidation.