Make a Go/No-Go Wear Gauge From Sheet Stock: A Shop Project for Edge Checks

Scenario: drivers eyeball how much edge is left and decisions vary from person to person. Direct answer: a go/no-go gauge cut from sheet stock turns the judgement into a quick yes or no against a limit you set. The limit itself comes from your supplier or fleet rules, and the gauge only enforces it. The numbers in the example are invented.

Template: build and use the gauge

Materials and tools

• Steel or aluminium sheet, thick enough to stay flat and not bend in a glove
• Marker, rule, calipers, saw or shears, file, drill and a hole for a lanyard
• Paint or tape in two colours and a permanent marker

Steps

1. Decide the limit. Ask your supplier or fleet manager what remaining height or thickness is the replacement point for your edge. Write it down with the source.
2. Measure a new edge. Use calipers to measure the same dimension on a new edge, so you know the starting point.
3. Mark the gauge. Cut a notch or step so the gauge sits on the steel face and its step shows when the edge is at or below the limit.
4. Check against calipers. Test the gauge on three worn edges you have measured. It should say go or no-go the same way as the measurement.
5. Paint it. One colour for go, one for no-go. Stamp or write the limit on the gauge.
6. Label and hang. Add the date, the edge type it fits and a lanyard.

Illustrative example (invented numbers)

Suppose a fleet decides to replace an edge once less than 20 mm of steel stands below the wear bar line. The gauge has a 20 mm step. If the step slides under the bar, it is a no-go.

Use and care

A home-made gauge is a good tool as long as it is checked against a reference.

• Check the gauge against calipers every season, since filing and drops change it.
• Make one gauge per edge type, labelled clearly.
• Keep a record of readings if you want trends.

A safety note

Deburr every edge of the gauge and wear gloves while cutting. A gauge with sharp corners is a hazard in a cab. Keep it in a pouch when not in use.

Boundary: The limit must come from your supplier or fleet rules; the 20 mm figure is invented for illustration and is not a recommendation.