I’m assembling a new piece of equipment, and there are a lot of machine screws and hex-head bolts.
I have learned a couple of tips over the years.
Tip 1: Read the instructions first.
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Tip 2: Think about the instructions.
So, the equipment I’m assembling has a small key fob remote, and it has to be paired to the machine. To do that, one has to take everything apart, tilt the bottom over, unfasten a panel, access the electronics, and then press a button before pressing a button on the remote.
The user manual doesn’t have things in logical order. Instructions for pairing the remote was on page 30. So, I had to remove some things to access the bottom panel.
Oh, and I also added the wrong swivel caster to a cart yesterday too, requiring me to take a moment to swap it for a locking caster.
Reading, heeding, and following instructions are different things.
Specifically regarding fasteners, I guess we can call that tip number 3.
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Tip 3: When faced with repetitive steps, do one first and then work in batches.
Slipping a washer onto a screw isn’t a big deal. If it’s done by mistake, there’s a difference between having to remove 16 washers compared to 160 (or more).
I did that once. I set up for a large assembly project and prepped all of my fasteners. Then, when it was time for the first step, I realized that I needed to install the fasteners and washers in a different order for things to fit properly.
Sometimes there’s a fastener and washer on one side of a panel or part, and washer and nut on the other. Other times there’s just a fastener on one side, and the washer goes on the opposite side.
Sometimes the instructions are low quality or inaccurate, other times I am overconfident in my comprehension of the task or steps involved. Completing one step and then repeating it has saved me a bunch of time compared to setting up for batch assembly and finding I wasted my time.
Similar “checks” are helpful in other types of projects. Test one, and then repeat for the rest.
Batch assembly can be efficient, but not when you have to backtrack.
Do you have any machine or equipment assembly tips?
Robert
One incentive I’ve found for buying Made in the USA is the instructions are usually better. Though to be fair, some major brands that out source their production overseas do pay attention to writing decent instructions. But in general I find Made in the USA to have better instruction manuals.
Stuart
“Buy products with better documentation” is rarely a feasible option for most types of products. Made in USA is rarely available.
I ordered vacuum equipment recently and the documentation is terrible. I spoke to someone on the phone before ordering, and they said they source from a local manufacturer. From the actual products I received and accompanying documentation, I’m convinced everything is just assembled here.
It’s shocking how poor documentation can be.
One company boasts USA-based documentation, but I found errors, inconsistencies, and omissions.
Documentation is typically outside of a user’s control.
Bonnie
Much like QC/QA, I think this has as much if not more to do with not buying the cheapest option. I’ve seen crap instructions from american companies that were little more than a bad xerox of an exploded diagram.
Jared
If it’s not something you intend to take apart, consider some loctite. Assembly is your one opportunity to do that without turning it into a major chore.
MM
You beat me to it. My personal rule is that whether the instructions say so or not, every threaded fastener gets either locite or anti-seize, as appropriate. Of course there are some exceptions where that would be inappropriate, but most of the time I am using one or the other.
A few other things I do:
-If the hardware seems unusually cheap or crappy for the application I upgrade it to better quality, higher grade, or stainless
-That goes double for things like hose clamps, hoses, casters, feet, knobs, and control handles.
-often times you can make flimsy assemblies a lot stronger by adding washers where there were none before, or swapping for larger or thicker washers compared to what the factory sent you.
-If I am putting bolts into blind threaded holes then I make sure to inspect the holes first, it may pay off to run a tap through to make sure there is no debris, paint, burrs, etc, in there.
-If the assembly involves electricity I always double-check that the power cable is suitably sized and properly grounded. Often times I upgrade to a better quality power cord, and/or add ground straps.
-Think about future maintenance and quality-of-life. If I am assembling something that requires lubrication I might add zerks, oil cups, or even a central lubrication pump. If a machine has a gearbox or sump with a drain plug I might consider installing a valve in its place, perhaps with a hose attached. Extra lighting (work or safety) might get added. Lock-out switches, E-stops, hour meters, or remote controls might get added. If the machine uses things like belts or bearing guides that wear out I make sure to write the size for replacements somewhere on the machine so it’s easy to find without having to dig through manuals.
-Apply constrained-layer damping material to sheet metal to make the machine quieter
-On some equipment gaps in guards or ducts can be a problem, so you might want to have RTV or suitable other material on hand to seal up holes and gaps as needed.
-Sometimes added mass is your friend. A device can be made a lot sturdier and vibration can be lowered by filling a hollow base or column with sand, cement, scrap metal, etc.
-Pneumatic tires get replaced with flat-free versions or at the very least filled with a generous amount of sealant.
Jared
That’s taking it WAY further – but I like it. I will sometimes clean up edges, run taps through holes, use higher-quality lubricants or fasteners, etc. – but I wouldn’t say I do that often unless I notice something obviously substandard.
Blocky
Having assembled a lot of things with poor tolerances— hand thread the screws to start them. For each step attaching one piece to another, get all the screws in plane started before tightening any, then check registration as you turn them to the point of friction-contact, and recheck as you snug them to the correct tightness.
If I’m assembling away from the bench, I’ll just bring my entire go-bag install kit to the project, bc more likely than not, I’ll have to run back for something – an insert bit, a prybar, an adjustable wrench, a flashlight, a chip brush, some delicate tape.
I am a person who cleans up sharp edges, so again, for the kind of low-fi assembly that I usually find myself doing, I may keep a file or a countersink handy. That delicate/painters tape is good for grabbing remnant swarf. Sometimes a little tape folded over is a good enough shim, or to keep two parts from scraping each other as they go together.
Never throw out the box or packing materials until you’re completely completely done, and maybe you should sleep on it once before deciding if you’re completely done.
fred
I recall a set of instructions for a bicycle – bought for a grandchild – it was made in Taiwan and came in sub-assemblies. I was always the bike guy in the neighborhood when my kids were growing up and over the years acquired a fair bike shop worth of tools to deal with British, French, Italian, Japanese and USA made bikes. So, I got the pre-Christmas assembly task. What I did not know was that for this bike I had to deal with a Taiwanese frame/fork with Japanese gear (Shimano) and a set of instructions printed in Spain. More than a little something seemed to have been lost in a Spaniard translating Chinese into English.
ElectroAtletico
I’m the only guy I know that reads the instructions for everything before I use/assemble. From start to finish, and repeat it in Spanish just to make sure I’ve not missed something. I hate watching YouTube vids in which the “influencer” just takes the instructions and tosses them aside.
Nathan
There’s been more than one time I’ve been better off tossing the instructions. Lol. But back to the idea though. Don’t forget to read the operating instructions too.
I’m probably one of a few that will read the book that used to come with a new car
Saulac
Inventory all fasteners and small parts before assembly. Know where each fasteners/small parts go. When you where things go, you can would understand the assembly process. Also when laying out all the fasteners and small parts, you would understand things like where the longer bolts should go.
MtnRanch
I made a pretty good career in the computer industry out of reading the instructions that others were too lazy to read.
Before buying a product, download the installation and operation manuals to see if they are well written. If not, move on to the next vendor before you buy yourself a life of grief and regret.
Peter
Reading the complete instructions and fully understand them before starting was something I learned the hard way when following recipes cooking.
On a side note, I am not sure why a lot of people have problems with Ikea’s instructions.
I find them straight forward and easy to understand you just need to follow them imho.
Joe
I rather enjoy assembling IKEA, or similar, furniture.
Key notes:
Get a pozidriv bit for an cordless screwdriver (I like my craftsman Gyro one)
Same for the hex bit, million times easier
I frequently add some wood glue to the dowels, especially when things are never going to be removed (screwed to wall, holes cut for outlets, etc.)
TomD
The hardest part with Ikea is making absolutely sure you’re using the right fastener in the way they intend; it’s way too easy to “know what they’re going to do” and end up realizing you used the slightly shorter screw.
CMF
What I usually do is grab the bag of fasteners, open it on a tray and separate them all to make sure everything is there, and then proceed with the instructions.
All the steps mentioned by MM and Jared are great, but do them if necessary. I don’t have the time to do it to everything I assemble.
Occasionally frustrating, but overall the assembly of…whatever is relaxing and fun.
MT_Noob
I like to try and download the instructions before the product arrives when possible. That gives me an early heads up on having the right tools and expectations. I also on occasion check youtube for any videos that might provide a time saving tip or two, or they might provide some tips on gotchas to look out for regarding possible product defects.