Whats Really Happening During the 2007/2008 Shop Rat Education Program?

posted on April 29th, 2008

Whats Really Happening During the 2007/2008 Shop Rat Education Program?

Class One:

We began class with introductions of all the students and the teachers revealing a bit of information about why we were in the program and other personal information. Next we moved into a safety and behavior workshop. Once we were finished we completed a model Hovercraft HANDS ON PROJECT that taught the students how to construct a small model hovercraft made out of foam and other materials. They followed directions from a manual along with completing worksheets that illustrated their knowledge of the parts of the hovercraft and how the hovercraft works.

Class Two:

We began class with an introduction in the industry of plastic manufacturing. Here we lectured on the processes of plastic manufacturing and watched three short clips on different types of plastic manufacturing. Once we learned about plastic manufacturing we constructed a Vacuum Molding Machine and performed a Plastic Prototype HANDS ON PROJECT that created a car prototype made out of plastic.

Class Three:

We began class with a review and oral test that covered the material learned in Class One and Class Two. Next we lectured on Inventory Management that covered the basics of inventory and its importance to all industries. We then completed an Inventory Control HANDS ON ACTIVITY where the students created an inventory control process for the Hovercraft parts that will be used to construct the full size hovercraft. This not only enforced the material learned that day, but also familiarized the students with the parts of the full size hovercraft.

Once the students finished their inventory Control HANDS ON ACTIVITY we had the National Association of Industrial Technologies present the different careers in Industrial Technology, Pay Scales, Associates and Bachelors Education Information among many other subjects to help inform the students of their choices for their future education and career.

Class Four:

We began class with Ed Redies, a pre-engineer and CAD instructor from the Jackson Area Career Center, teaching the students about basic blueprint reading. Here they learned about the views and lines of the blueprint among many other key skills of basic blueprint reading. Along with a lecture students watched a short film about blueprint reading and took part in a small hands on activity where they learned to draw a simple blueprint.

Once the blueprint lesson was complete students had a chance to meet Matt Starbuck, a hovercraft builder from Port Huron. He shared with the students his life as a Shop Rat and the history behind hovercrafts. Matt Starbuck brought two of his finished hovercrafts and let each of the students operate one of his hovercrafts. We taught the students how to operate the hovercraft using this HANDS ON ACTIVITY and gave many insights on how to build the craft. Once the outdoor activities were complete many students and parents stuck around to learn even more practical tools for building the hovercraft.

Class Five:

We began the class with a written test that will be used to assess the students knowledge on the material covered. Once the test and review of the test was complete, we lectured on how to use a tape measurer and how to scale on object. Worksheets were then completed by each student to help understand both measurement and scale. Next we discussed and provided a handout that shared the Job of the Week which was a construction worker. Here we discussed everything from the level of education needed to the pay scale for that career.

Once the lectures were complete we moved into the Hovercraft Hull Scale HANDS ON PROJECT. The students began by using a printed scale model of the hovercraft hull that was taken from the actual hovercraft blueprint. Next, in order to know exactly how to cut the foam in order to use the Foam Material that is provided for the full size hovercraft, they used scale foam sheets to create their own scale model of the hull. Here they learned how to use the least amount of material to create the parts necessary for the hull. They also learned about the concept of ‘joints’ and learned how to put two layers of pieces together so that the joints do not overlap. The students used a significant amount of math and measurement to complete this project.

Class Six:

We began class with a lecture from Ed Redies, a JACC Pre-engineer and CAD Teacher. He taught the students how to draw the tooling that they were going to create and also taught them how to scale it up and how to scale it down using math concepts. Once the students understood what they would be building we introduced them to the Job of the Week which was a plumber as they were going to be doing some pipe cutting, soldering and fitting. Once the students learned about being a plumber they learned about all the safety rules while working on the machines that they were going to be using for the HANDS ON PROJECT. Next the students formed into three groups and rotated through the three different HANDS ON ACTIVITIES. 1. Students Cut Foam Pieces to form the scale hull of the hovercraft while using the tooling that the other groups were creating. 2. Students cut, prepared, soldered and put together copper pipes and formed the handle and body of the tooling. 3. Students machined a substance called Delron to create the spacers and other parts for the Tooling.

Class Seven:

We began class seven with a HANDS ON PROJECT that involved the students taping the layers of the scale model of the hovercraft hull together and using vacuum bagging to compress the layers using the weight of suction. Once the students were complete with the vacuum bagging project, we taught the students about the different types of templates, jigs and fixtures that are used in the skilled trades’ environment. Once the lecture was complete the students then learned about the job of the week which was a Tool and Die Maker. Here they learned about the duties, requirements and pay scales of the Tool and Die Makers. Once they learned all about our job of the week we moved into our next HANDS ON ACTIVITY which was cutting the foam using templates and power tools to create the pieces needed for the hull of the full size hovercraft. The students first laid the templates over the foam, and traced guidelines of where the foam needed to be cut. Once the guidelines were in place, the students used a saber saw to cut out the pieces required for the full size hovercraft hull.

Class Eight:

We began class with a hands-on science and teamwork project called the Egg Drop. The students first learned about gravity and other important forces in science that caused an egg to break when it was dropped. Once the lecture was complete the students learned about the Shop Rat Job of the Week, a Package Development Engineer. Here they learned about the duties of an engineer and the qualifications needed to become one. Next the students learned about teamwork and the principles of creating a better outcome when working in teams. Once the students gained an understanding of the science behind the activity, the principles of teamwork and looked at a career in Package Design the students broke off into two teams where they had 30 minutes to design, construct and test the egg package that would be used to protect the egg during the egg drop. After the 30 minutes were up an instructor dropped both packages from about a nine foot height and both teams passed the challenge.

Once the students cleaned up, they completed a test to asses the students understanding of past material. After the test the students took part in a HANDS ON ACTIVITY which was cutting foam using templates and power tools to create the second layer of the hovercraft hull. Once the HANDS ON ACTIVITY was complete the students filled out a survey that assessed the class and activities so we have a better understanding of what the students like and dislike for future classes.

Class Nine:

We began class with a lesson on Fiberglass, Resin and Hardener. During the lesson the students learned what fiberglass is, the different forms of fiberglass, what resin and hardener is and what the end result of using them together can be. Next the students learned about the Job of the Week which was a Fiberglass Fabricator. Here they learned about the tasks and duties, education and training requirements and the pay scale for a Fiberglass Fabricator.

After a short break the students learned how to mix the resin and hardener together so that it was the right consistency for the HANDS ON ACTIVITY. Next they measured and cut the fiberglass into strips to cover the Hovercraft Hull Joints. They then placed the fiberglass strips over the hovercraft hull joints. They painted the resin over the fiberglass strips and bonded the hovercraft foam pieces together, finally creating a solid hull.

Class Ten:

We began class with a lesson taught by Ed Redies that explained how the treads of a screw worked, how they can be measured with calipers and the tap drill size for standard threads. Once the thread lesson was complete the students learned about the different types of wood; Hardwood, Softwoods, Plywood’s and water resistant woods.

After a short break the instructors gave a short safety lesson about the HANDS ON ACTIVITY for the day. Once the students understood the safety precautions of the project they broke off into three groups and completed the following activities: 1. Used tooling to cut an angle on the edge of the hovercraft Hull. 2. Sanded the areas of the Hovercraft so that the angle that was cut was smooth and led right into the top. 3. Created a template for the piece of the hull in which the skirting will attach to. 4. Begin to cut the pieces for the hovercraft in which the skirting will attach to.

Class Eleven:

We began class with a PowerPoint presentation of Work Ethics- Performing for Success. With presentation taught the students the importance of having a positive work ethic and the top ten positive work ethic traits. The presentation ended with showing a clip of Jack Roush sharing his thoughts on having a good work ethic. This video clip can be seen at http://www.shoprat.org/videos.php.

Once the Work Ethic Presentation was complete the instructors explained to the students a new method that was going to be implemented into the program; leadership. Each week the students will be placed into groups and one leader will be elected to guide their team through the hands on projects. This will help to promote leadership skills and teach the students about working together as a team.

The students were placed into three separate groups and completed the following HANDS ON ACTIVITIES: 1. Measuring and cutting the Plywood layer of the Hovercraft Hull (Team Leader: Zak Mudge). 2. Continue measuring and cutting the inside skirt attach strip. (Team Leader: Anthony Hoard). 3. Using the template to measure and plot the Thrust Duct. (Team Leader: Tyler Denig).

Class Twelve:

We began class with a lesson on Carbon Fiber Composites. During this lesson the students watched a PowerPoint presentation that explained what a composite is, what composite manufacturing is, the benefits of composites, carbon fiber technology, careers in composites, job types, composite employers and salary information. Once this was complete the students completed an exercise called “Good Work Ethic vs. Bad Work Ethic” that distinguished the difference between the two.

Next, students were broken up into teams and completed the following HANDS ON ACTIVITIES: 1. Continued Cutting the Plywood layer of the Hovercraft Hull (Team Leader: Peter Kueffner). 2. Continued measuring and plotting the Thrust Duct and determining the location of the slots to be cut. (Team Leader: David Tracy) 3. Created template for the wood piece that will attach to the skirt attachment piece of the hovercraft (No Team leader, only two students needed for this activity).

Class Thirteen:

We began class with a lesson on Thrust. With a balloon demonstration the students understood the basics of thrust. We then explained in more detail the dynamics of thrust with examples of how it works with different components. We then watched a short movie on the Thrust SSC, a car that broke the sound barrier of 743 miles per hour.

Once the Thrust lesson was complete the students completed a teamwork activity in which they worked together as a team to form a line from the earliest birth month to the latest birth month in the year without speaking, lip reading or other methods.

Next the students learned the Shop Rat Spotlight Job of the Week, HVAC. Here they learned the duties, educational requirements and salary information for a HVAC Professional.

Next, students were broken up into teams and completed the following HANDS ON ACTVITIES: 1. Cutting out the Thrust Duct and created a tool to cut the edges in order to attach the two pieces together (Team Leader: Ben Joseph) 2. Trimming the edge of the Hovercraft and preparing to fix unglued edges (Team Leader: Evan Kueffner). 3. Preparing and beginning to cut the plywood pieces to attach the skirt attachment piece to (Team Leader: Anthony Lilianthal).

Class Fourteen:

We began class with a PowerPoint presentation on the lathe. The students learned the history of the lathe, the different types of lathes, products of the lathes and many other aspects of that lathe. Once the presentation was complete the students reviewed the Shop Rat Job of the Week a CNC Lathe Operator and Programmer. Next we reviewed the hands on projects for the day and took a break. Once break was complete, the students were broken up into teams and completed the following HANDS ON ACTIVITIES: 1. Finish cutting the plywood pieces to attach the skirt attachment piece to. 2. Cut strips of wood to wrap around hovercraft hull. 3. Glued ‘unglued’ areas of the hovercraft hull.

Class Fifteen:

We began class by learning the different parts of the Lathe. The students watched as the instructor demonstrated how each part of the lathe worked. Next, the students reviewed the different cutting tools used in a lathe. Once the lesson of the lathe components and cutting tools were complete, the students reviewed the Shop Rat Job of the Week, Masonry. Next we reviewed the hands on projects for the day and took a break. Once break was complete, the students were broken up into teams and completed the following HANDS ON ACTIVITIES:

1. Cutting out Fiberglass Pieces
2. Sanding the foam
3. Cutting foam with Hotwire tool
4. Trim edges from the hovercraft
5. Build a hammer project on the Lathe

Class Sixteen:

We began class with a quick review of the different parts of the Lathe. Once this review was complete the students were broken up into teams and completed the following HANDS ON ACTIVITIES:

1. Continue Sanding Hovercraft hull pieces
2. Fiberglassing the fiberglass strips to the hull
3. Continue trimming edges using the hotwire tool
4. Completing other various activities for the hovercraft.

Class Seventeen:

We began class with a presentation of the Mill. The instructor demonstrated how to use the mill and how all the components worked. Once this presentation was complete the students participated in a review game called “hot potato” or “hot tool” for this game. The students were given review questions from the material covered throughout the year and if they got the question right they got to pass the hot tool. The tool kept rotating throughout the students until the timer went off. The student holding the tool when the timer goes off has to then step out of the circle. The game goes until there is only one student standing. Congratulations to Scott Watson as he was the winner for this competition.

Once the review game was complete, the students learned about the Shop Rat Job of the Week, a Construction and Building Inspector. Next, the students took a short test on the components of the lathe. Once the test was complete we took a short break.

After break the students were broken up into teams and completed the following HANDS ON ACTIVITIES:

1. Mini Hovercraft – Snow Blower
2. Completing other various activities for the Large Hovercraft
3. Lathe (Hammer Project)

Class Eighteen:

We began class with a team work exercise where we broke the students into two teams and they created their own team name, team slogan, and brainstormed 10 possible modifications that would make the mini-hovercraft Shop Rat Tough. Once the team work exercise was complete we reviewed the projects that were going to be completed today then took a break. After break, the students completed the following HANDS ON ACTIVITES:

1. Measuring and begin cutting out plywood for the hovercraft cock pit.
2. Created a second platform (base) for the mini hovercraft
3. Lathe (Hammer Project)

Class Nineteen:

We began class with a review of our behavior and safety policy. Once this review was complete the students watched a video that showed how Airplanes and Harley Motorcycles are built. The students completed a test while watching the videos. Once these presentations were complete the students learned about Wyotech, a technical school and their Motorcycle Technician program that they had available. The students learned about a career as a Motorcycle Technician. Once the students were complete with the Shop Rat Job of the Week they took a short break. After the break, the students completed the following HANDS ON ACTIVITIES:

1. Finish cutting out plywood for the hovercraft cock pit.
2. Continue to work of Mini Hovercraft (design enhancements )
3. Lathe (Hammer Project)
4. Cut the wood for the thrust Duct
5. Created duct templates
6. Mocked up cock pit area on the hovercraft hull

Class Twenty:

We began class with a presentation on electric cars. The students learned how an electric car works. They also learned about the ‘Buckeye Bullet’, the worked fastest electric car and learned how the car was designed using SolidWorks software. The students then watch a few videos that described the SolidWorks program and its capabilities. Next, the students learned about the Shop Rat Job of the Week, an ironworker. Once the Job of the Week was complete, the students took a break and then begun the following HANDS ON ACTIVITIES:

1. Cut out Plywood for the Thrust Duct
2. Work on the Engine Mount
3. Fibergalssing the Hull and Thrust Duct
4. Work on the mini hovercraft

Class Twenty One:

We began class with a scientific experiment to explain how hydro power works. The students completed the experiment then learned the process and background of hydropower by watching a detailed movie. After the students understood Hydro-power they were introduced to the Shop Rat Job of the Week, a Marine Mechanic. Once the understood the pay scales, duties, and experience needed to become a marine mechanic they took a short break before moving on to the following HANDS ON ACTIVITIES:

1. Fiberglassing the Hovercraft Hull
2. Creating Side Panels for the Mini-Hovercraft
3. Sanded the foam on the Hull
4. Worked on the Lathe (Hammer Project)

Class Twenty Three:

We began class with a review on acceptable behavior and introduced a new cleaning policy so that the class can work as a team to keep up the condition of the classroom. Once the students understood the new policies they then learned how to create an object from a blueprint. The students were given prints in which they were to create the object on the print using paper, scissors and tape. Once the students created the object students learned about Quality Control. They then completed a quality inspection on the objects that were created. They also learned about the Shop Rat Job of the Week, a quality control manager. Next the students took a short break before moving onto the following HANDS ON ACTIVITIES;

1. Continue to fiberglass the hull
2. Paint Mini Hovercraft
3. Cut pieces of wood for the cockpit
4. Fit motor mount into thrust duct
5. Fit lift duct into the hull

Class Twenty Four:

We began class with a review on how to draw a blueprint. After reviewing the top, front and side views the students began a competition. This competition entailed teams building the tallest building possible using only three sheets of paper. The students were then required to draw a print of the building although we ran out of time during this week’s class. Next the students took a break before moving onto the following HANDS ON ACTIVITIES;

1. Continue to sand the hovercraft
2. Continue to fiberglass the ducts
3. Glue and fiber glass the mount
4. Lathe (Hammer Project)

Class Twenty Five:

Because of a winter storm there were only a few students. So, we decided to have a ‘free’ day where the students could decide what they wanted to work on. So, half the students worked on the hovercraft and half the students built a model house using a cardboard architecture kit.

Class Twenty Six:

We began class with finishing the 'tallest building' project. Once the students were done with the design and the building was able to stand for at least 30 seconds the student then drew a blueprint of the top, side, and front view of their design. Once the drawings were complete, students took a short break and moved on to the following hands on activities:

1. Draw layout for the dashboard
2. Construct the Rudders
3. Built the temporary seat
4. Hammer Project (Lathe)

Class Twenty Seven:

We began class with a model airplane project. The student followed a manual, working as teams to construct a junior model airplane. Once the students were complete with this project they learned about the Shop Rat Job Of the Week, an architect. After the Job of the Week the students took a short break before taking the hovercraft outside. The students took turns taking the hovercrafts for rides and getting a feel for how the hovercraft is operated. Once the outside rides were complete students wrapped up class by flying their model airplanes and competing to see who's airplane would stay flying the longest!

Class Twenty Eight:

We began class with a project called Teamwork in Aerospace. A project, provided by NASA allows students to form a company, receive a RFP to build a plane for NASA, construct the plane and compete to win the contract. Once this project was over the students took a short break before dissembling the entire hovercraft and sanding the fiberglass to prepare the craft for paint.

Check out Photo’s from the 2007/2008 Shop Rat Education Program! (copy and paste link in your address bar)

http://www.shoprat.org/photos.php?cid=23&title=1.+2007%2F2008+Shop+Rat+Education+program