SUBJECT:

METER
DOC REF:
REVISION

1.

DURALECTRA-CHN WORK INSTRUCTIONS

CONSTRUCTION OF A PAS

ORIGINAL DATE ISSUED:

REVISION DATE:
Page 1 of 15

3/16/2016
3/16/2016

PURPOSE

The purpose of this document is to provide a detailed work instruction

on the construction of a PAS meter. The document is designed to outline the
operators needs including, tools, material, and an easy to follow, step by
step guide.
2.

APPLICATION

The PAS meter is utilized in our production line to assist in determining

processing current density when it is difficult to calculate surface areas of
geometric parts. Each process will require a different current density
depending on its type of anodizing. The PAS meter will confirm the in-tank
CD value during process.
3.

ASSOCIATED DOCUMENTS

4.

3.1

QM-01-100 Quality Manual

3.2

QP-09-100 Process Control Documents

3.3

QP-O9-300 Preventive Maintenance C

3.4

WI-01-100 Personal Safety Policy

INSTRUCTIONS
4.1

Equipment & Materials

MATERIALS
-

1 x x 29 AL spline

1 x 3/8 x 8 AL hook
1/8 rubber sheet
-20 x 1 copper or brass bolt
-20 x 1 copper or brass bolt
50 Amp meter from Grainger
Model 12G422
6x4x2 project enclosure from

ID x OD copper
washers
-20 copper or brass nuts
4 gauge red cable
4 gauge black cable
4 gauge ring terminals
Loctite color guard (blue
plasti-dip)
- 20 UNF Ti hex nut

SUBJECT:
METER
DOC REF:
REVISION

DURALECTRA-CHN WORK INSTRUCTIONS

CONSTRUCTION OF A PAS

ORIGINAL DATE ISSUED:

REVISION DATE:
Page 2 of 15

RadioShack
Ti lock washer

3/16/2016
3/16/2016

- 20 Ti hex head bolt

5/8 flat .003 x 1.188 OD Ti
1 sq. ft. aluminum (6061) panel
washer
Table 1: Material required to construct a PAS meter.

EQUIPMENT
Cordless drill
2 hole drill
1/2, 5/16 and 3/16 drill bits
3/8 ratchet
7/16 socket
7/16 wrench
Straight edge or ruler
Xacto knife or box cutter
Wire brush
Drill press
Table 2: Equipment required in order
4.2

Channel lock
Measuring tape
Center punch
De-burring tool
Paint brush
Rotary grinder/wire brush
Multi-meter or continuity tester
Horizontal band saw
Phillips head screwdriver
Flat head screwdriver
to construct a PAS meter

Precautions

When operating/handling heavy machinery and chemicals, always

make sure to take the necessary precautions to ensure your own safety and
the safety of others. Always where the proper PPE and report any concerns
you may have to your supervisor.
4.3

Procedure

Using stock 1 x aluminum bar, measure 29 and cut using a

band saw. Remove any burrs and sharp edges with the rotary grinder and
wire brush.

SUBJECT:
METER
DOC REF:
REVISION

DURALECTRA-CHN WORK INSTRUCTIONS

CONSTRUCTION OF A PAS

ORIGINAL DATE ISSUED:

REVISION DATE:
Page 3 of 15

3/16/2016
3/16/2016

Figure 1: 29 x 1 x aluminum spline.

To begin the preparation of the aluminum hook, use a stock 1 x 3/8
pre-formed hook. Measure and cut the stock hook to a total length of 8 with
a band saw and remove all burrs and sharp edges with the rotary grinder and
wire brush.

Figure 2: 8 x 1 x 3/8 aluminum hook.

Using the drill press, drill one hole on one end of the spline and three
5/16 holes on the other end of the spline using Figure 3 and 4 for the
correct dimensions of where to drill.

SUBJECT:
METER
DOC REF:
REVISION

DURALECTRA-CHN WORK INSTRUCTIONS

CONSTRUCTION OF A PAS

Figure 3: hole
spline.

ORIGINAL DATE ISSUED:

REVISION DATE:
Page 4 of 15

3/16/2016
3/16/2016

drilled at end of

Figure 4: Three 5/16 inch holes drilled at the other end of the spline.
On the hook, drill two 5/16 holes using Figure 5 for the correct dimensions to drill.

SUBJECT:
METER
DOC REF:
REVISION

DURALECTRA-CHN WORK INSTRUCTIONS

CONSTRUCTION OF A PAS

ORIGINAL DATE ISSUED:

REVISION DATE:
Page 5 of 15

3/16/2016
3/16/2016

Figure5: Two 5/16 inch holes drilled in the aluminum hook.

To begin the customization of the project enclosure, starting with the lid,
measure to the center and drill a hole for the amp meter using the 2 hole
drill. Measure accordingly around this hole for the screws on the amp meter
to fit properly and drill 4 holes with a 3/16 drill bit. The amp meter will come
with stock lock washers and nuts to assemble to the enclosure lid. See Figure
6 and 7 for measurements and assembly.

SUBJECT:
METER
DOC REF:
REVISION

DURALECTRA-CHN WORK INSTRUCTIONS

CONSTRUCTION OF A PAS

ORIGINAL DATE ISSUED:

REVISION DATE:
Page 6 of 15

3/16/2016
3/16/2016

Figure 6: Enclosure lid with 2 hole in center and four 3/16 holes to fit
amp meter.

Figure 7: Amp
assembled to lid with stock lock washers and nuts.

meter

For the case portion of the enclosure, drill two 5/16 holes on the back side.
See Figure 8 for the proper dimensions.

SUBJECT:
METER
DOC REF:
REVISION

DURALECTRA-CHN WORK INSTRUCTIONS

CONSTRUCTION OF A PAS

ORIGINAL DATE ISSUED:

REVISION DATE:
Page 7 of 15

Figure 8:
holes
the

3/16/2016
3/16/2016

Two 5/16
drilled in
backside of
the enclosure.

To insulate the hook and the spline, a 3.5 x 1.5 pc of rubber will need to be
cut using scissors or a utility knife. Using Figure 9 below to measure the
correct position, drill two 5/16 holes through the rubber with a cordless drill
or drill press.

Figure 9: Rubber insulator with two holes drilled out.

SUBJECT:
METER
DOC REF:
REVISION

DURALECTRA-CHN WORK INSTRUCTIONS

CONSTRUCTION OF A PAS

ORIGINAL DATE ISSUED:

REVISION DATE:
Page 8 of 15

3/16/2016
3/16/2016

A 1 x 1 piece of rubber with a 5/16 hole drilled in the center will also be
required to insulate some of the hardware that will eventually secure the
hook, spline, etc. together.

Figure 10: 1 x 1 rubber insulator with 5/16 hole drilled in the center.
To begin the assembly of the pre-fabricated materials you will need one
- 20 x 1
brass bolt and two - 20 x 1 brass bolts. Wrap electrical
tape on one the one 1 bolt and one of the 1 bolts like in Figure 11.

SUBJECT:
METER
DOC REF:
REVISION

DURALECTRA-CHN WORK INSTRUCTIONS

CONSTRUCTION OF A PAS

ORIGINAL DATE ISSUED:

REVISION DATE:
Page 9 of 15

3/16/2016
3/16/2016

Figure 11: Electrical tape wrapped brass bolts to insulate the hook and spline
during assembly.
When assembling the hook and the spline make sure the two insulated bolts
are used, the uninsulated bolt will be used for the third hole in the spline and
will not contact the hook. Make sure the 3.5 x 1.5 rubber insulator is
between the hook and spline properly and the electrical tape on the bolts is
wrapped far enough down the thread to insulate conductivity from the spline,
but allow enough room to thread on a nut. The 1 x 1 piece of rubber will
be used to insulate the top of the 1 bolt from the hook and can be
secured with a - 20 nut. Do no secure the middle 1 bolt and the
uninsulated top 1 bolt just yet.

Figure

12:
Beginning the assembly of the hook and spline.

SUBJECT:
METER
DOC REF:
REVISION

DURALECTRA-CHN WORK INSTRUCTIONS

CONSTRUCTION OF A PAS

ORIGINAL DATE ISSUED:

REVISION DATE:
Page 10 of 15

3/16/2016
3/16/2016

Place the pre-drilled enclosure over the top two bolts and secure it in place
with two - 20 nuts.

Figure 13:
assembled and
At this point in the
make sure that
spline have
insulated and that
electrical contact.
checked with a
light. Proceed with
test light does

Enclosure
secured.
assembly is to
hook and the
remained
there is no
This can be
continuity test
assembly if the
NOT light up. If

SUBJECT:
METER
DOC REF:
REVISION

DURALECTRA-CHN WORK INSTRUCTIONS

CONSTRUCTION OF A PAS

ORIGINAL DATE ISSUED:

REVISION DATE:
Page 11 of 15

3/16/2016
3/16/2016

the test light does light up, double check that insulation is not compromised,
and that hardware is properly insulated where necessary.

Figure 14: Checking to make sure there is NO electrical continuity between

hook and spline.
Once the hook, spline and enclosure are assembled properly, put the
- 20 Ti bolt, 5/8 Ti washer and - 20 Ti nut through the hole drilled
through the spline. The nut and the washer should be on the side of spline
with the enclosure, which would make the bolt on the side with the aluminum
hook. The spline can now be painted with the Loctite color guard to protect
the aluminum from breaking down throughout use and affecting surface area
calculations. When painting the spline, be careful not to paint over the Ti
washer and nut since contact will be required on this surface. The Ti bolt on
the other side of the spline should be painted over. The paint is only
necessary to extend to roughly 2 before the first brass bolt. The process will
require 4 5 coats of Loctite color guard allowing 40 60 min to cure
between each coat.

SUBJECT:
METER
DOC REF:
REVISION

DURALECTRA-CHN WORK INSTRUCTIONS

CONSTRUCTION OF A PAS

ORIGINAL DATE ISSUED:

REVISION DATE:
Page 12 of 15

3/16/2016
3/16/2016

Figure

15:
Enclosure side of painted spline with Loctite color guard.

SUBJECT:
METER
DOC REF:
REVISION

DURALECTRA-CHN WORK INSTRUCTIONS

CONSTRUCTION OF A PAS

ORIGINAL DATE ISSUED:

REVISION DATE:
Page 13 of 15

Figure

3/16/2016
3/16/2016

16:
Hook side of painted spline with Loctite color guard.

To begin the wire preparation, cut 5 of both one black and one red 4 AWG
cable. Remove roughly 1/2 of the cable insulation from each end and secure
a 5/16 ring terminal to both ends with terminal crimpers.

SUBJECT:
METER
DOC REF:
REVISION

DURALECTRA-CHN WORK INSTRUCTIONS

CONSTRUCTION OF A PAS

ORIGINAL DATE ISSUED:

REVISION DATE:
Page 14 of 15

3/16/2016
3/16/2016

Figure 17: Red and black 4 AWG wire with 5/16 ring terminals.
These wires can be hooked up to the amp meter with the standard hardware
that came with it. Make sure to hook the red wire up to the terminal that is
labeled positive (+) on the back of the meter.

SUBJECT:
METER
DOC REF:
REVISION

DURALECTRA-CHN WORK INSTRUCTIONS

CONSTRUCTION OF A PAS
ORIGINAL DATE ISSUED:
REVISION DATE:
Page 15 of 15

3/16/2016
3/16/2016

Figure 18: 4 AWG wire hooked up to the amp meter.

Revision(s) Index
Rev.

Date

Originator

Section

Description of
Changes