Metalshop Area

General Information

MakeICT's metal shop is an open 1236 sq ft area dedicated to metal working with shared space for bicycle repair.

Jeremiah Loder is the Benevolent Dictator over the metal shop.

Metal Shop Wish List

A list of equipment or tools that the metal shop would like to obtain. If you would like to donate one of these tools please contact the BD before dropping the tools or equipment off.

• 2x72 Belt Grinder - To allow us to facilitate knife making classes. This size belt grinder is useful due to the large number of belts available, from super course to super fine, including scotchbrite and leather for polishing work. Thanks to Jerry Carpenter for donating the motor and brought our cost down and the Board approved this tool to be built!!
• Foundry for smelting aluminum - I have found one on-line for about $200 for a kit that we would then build on site. Would still need the refract(?) material and plumbing for propane attachments.
• Bicycle Tools - This would allow members to do maintenance and repair on their bikes. We have already been gifted with a spoke machine and wheel truing stand.
• CNC Plasma cutting table. I would like to get one in either 4x4 or 4x8. This would be an awesome addition to the metal shop and would be a lot more approachable than the Tormach.
• Hoist for Bike Lift - Would like to build a lift/bike rack to hoist bikes into the overhead of the metal shop to facilitate storage for long term projects and to use as a bike rack without cluttering the metal shop during busy times. We would like to make the rack out of old bicycle frames, If you have any laying around please contact me before donating them.

Machine Access Policy

Metal working tools are hazardous. Before anyone may use the tools, they need to attend a shop safety class and be approved for tool use. We want everyone to go home safe and in one piece! SAFE OPERATION of tools is top priority.

While not required, we strongly suggest that anyone who wishes to work in the metal shop has a tetanus vaccination. We only get one life and one body to destroy, poisoning from rusty metal is a bad way to go.

We strongly suggest that while tools are in operation, anyone entering the shop use personal protective equipment (PPE) such as safety glasses, hearing protection, and hand protection.

It is HIGHLY recommended that we use a buddy system, where no single person is working in the shop without a second person in the building so that if there is an injury, somebody else is there to call for help or assist you.

General Shop Safety

1. Do not use any machine you are not comfortable using. If at any time you are unsure of what you are doing, stop immediately and ask for help.
2. Do not use any machine that is not in good working order. Stop, unplug and leave a note on the machine and notify the metal shop BD-Jeremiah Loder.
3. NEVER ASSUME A TOOL IS PROPERLY ADJUSTED. Always check the tool prior to use.
4. Wear safety glasses at all times when tools are in use in the shop area.
5. Ear protection is also recommended, many of the tools operate above 90 decibels and without protection, you are losing hearing.
6. When working in metal shop:
   • No open-toed shoes or loose clothing (remove drawstrings)
   • Remove objects on hands and wrists (including rings, bracelets, & watches)
   • Remove dangly necklaces, hair ornaments, and earrings
   • Restrain long hair to prevent entanglement
   • Natural fiber clothing is required for all hot work. Synthetics can melt to your skin.
7. Do not leave machines running unattended.
8. Never talk to or disturb anyone operating power tools, forge or welding equipment. If you must talk to an operator wait until the operator finishes the operation.
9. Be aware of the work going on around you. Do not accidentally bump into another person or their materials while they are working. Don't forget you can be harmed by the actions of those around you in the metal shop.
10. Most shop accidents are caused by working tired, rushed or distracted. As you get more experience, you will learn to listen to the little voice in the back of your mind that says, you probably shouldn't do that. Stop and think, there is usually a safer way of performing that function. These machines do not have a brain, please use yours!

Metal shop Safety

1. Smoke is not always a bad sign in the metal shop, but you need to be aware of the situation you are in. Smoke is a hazard to your health, so when doing operations that cause smoke, please try to limit it and have proper ventilation.
2. No wet or damp items of any type (including drink containers, rags, or hands) may be placed or left on machine surfaces as they will corrode.
3. Do not lean or sit on machinery.
4. You are responsible for cleaning your machines, your work space, and putting all tools away after use. Scrap metal should be placed in designated locations. Use vacuums or hand brushes to clean machinery.
5. Users who consistently fail in their clean-up responsibilities may be denied shop access.
6. Make sure machines are in the “off” position and motion has stopped, before leaving them after use.
7. Make sure all gas cylinders are in the off position while not in use.
8. All safety guards must be kept in place while operating equipment. If a guard or safety device is an impediment to safe operation of a machine - ask for help.
9. Use equipment only for its intended use.
10. If you have made an adjustment to a piece of equipment, return it to its normal position after you are done.
11. Make sure the machine’s work surface is unobstructed and clean before use.
12. Always be aware of the proximity of moving machine parts to body parts - fingers.
13. Metal can be hot even though it doesn't look like it, beware of burns.
14. Metal is heavy and can cause injury if falling.
15. All guests are the responsibility of the member. Guests are NOT allowed to use equipment. This is a working shop, so children less than 7 years old are not allowed for safety.

Machine shop Specific Safety

1. This includes all mills and lathes in the metalshop.
2. BD or authorized peer certification is required to operate this equipment. This can be as easy as showing the BD or peer the proper use of said equipment and describing experience.
3. Due to the high level of technical understanding and cost of the Tormach CNC mill, extensive training will be required before use.
4. All work shall be secured properly and all loose objects removed from tables before machines are operated.
5. Milling cutters and other hardened tools shall not be struck with steel hammer. Blocks of wood, rawhide, or copper hammers should be used.
6. Proper feeds and speeds shall be selected before operations are started.
7. Machines shall be stopped before any attempts are made to measure or to check work.
8. Guards and baffles shall be used to protect others from flying chips, oil or coolants.
9. Most all equipment has pinch point or crushing areas that you need to be familiar with before using that equipment.

Welding shop Specific Safety

1. Member is responsible for using welding curtains to protect other people in area from weld flash hazards.
2. ALWAYS wear a proper face shield when grinding and a welding helmet when welding.
3. ALWAYS wear closed-toed shoes, no excuses!
4. It will make you more comfortable to wear a long-sleeved, non-flammable shirt such as a welding jacket while welding.
5. Wear the appropriate glove while welding.
6. We suggest you wear ear protection (earplugs or muffs) to prevent sparks from entering your ear canal. An eardrum punctured by a spark will instantly cauterize and never heal.

Fumes

1. NEVER weld on or near anything that's been cleaned with a chlorinated hydrocarbon like brake-cleaner. When combined with UV light, chlorinated hydrocarbons can create phosgene gas, which can cause serious injury or death. Ventilation will not prevent poisoning.
2. No galvanized (zinc plated) material should be welded without removal of the galvanized coating near the weld zone to protect from poison gas release.
   • Welding Fumes and Gases Fact Sheet
   • Metal Fume Fever

Fire

1. Make sure the hot work area is free from all flammable materials such as flammable liquids, paper, etc. Do not wear clothing or gloves that have been exposed to flammable liquids.

Electrocution

1. Before turning on a welding machine, make sure there are no puddles of water on the floor around the weld bench or the machine. Make sure the welding machine is dry, including the main box, the torch and the plug.
2. There is little risk of fatal electrocution from a properly working MIG weld machine.

Burns

1. Welded metal will remain hot for several minutes after it is welded and will not be obvious of the heat retained. In most cases the heat is localized near the weld itself but you cannot tell by looking.
2. MIG welding steel will create sparks, so earplugs and full coverage safety glasses should be worn to prevent burns to sensitive tissue.
3. Gloves must be worn when welding and handling recently welded material. Deerskin or heavy-duty insulated welding gloves give the best protection, but you can choose the glove that is right for you.
4. If you burn yourself, immediately cool the wound, seconds count! We will keep burn cream in the fridge, apply asap! Burns will happen, just a part of metal working.

UV Burns

1. The light emitted from a weld arc is brighter than that of the sun. Do not look at the arc without wearing a full-faced welding mask with a shade 9 or darker filter plate. Always make sure the weld curtains are in place between the welder(s) and other people in the shop. You will be more comfortable if you cover any exposed skin, including cuff and collar areas, while welding or observing inside the weld area. The rays from the arc can cause a UV burn much worse than a sunburn.

Compressed Gas Cylinders

1. Argon and CO2 are inert, nontoxic gases normally present in the atmosphere. However, if allowed to fill an enclosed area these gases can fully displace breathable air, causing asphyxiation and death. Greater potential danger is the valve being knocked off the cylinder, turning it into a rocket powerful enough to severely injure or kill people and damage equipment and the building itself.
2. The following guidelines must be followed at all times:
   • Storing
     • Cylinders must ALWAYS remain upright and NEVER be placed horizontally.
     • Cylinders must be secured with a non-combustible material (metal) to an immovable object to prevent them from falling.
   • Moving
     • Cylinders must be securely capped.

Equipment List

Picture	What	Manufacturer	Model	Power	Status	Expert	How To
	4 Axis 34" x 9.5" CNC Mill	Tormach	PCNC 1100	220	Working	Curt Gridley	[manual]
	12"x 35" Metal Gear Head Lathe	Logan-Powermatic	2557TH	220	Not set up yet	??	File:Logan manual.pdf
	12" Metal Lathe	Craftsman	101.28990	110	Working	??	File:Craftsman Lathe manual.pdf
	MIG Autoset Welder	Miller	Millermatic 211 Autoset	220	Working	Jeff Eck	File:Miller211 manual.pdf
	Plasma Cutter	Hypertherm	30 XP	220	Working	Jeff Eck	File:Hypertherm30XP manual.pdf
	Welding Helmet	Chicago Electric	91214	solar	Working	Gavin Rondeau	File:WELDING HELMET.pdf
	4-1/2” Paddle Angle Grinder	DeWalt	DWE402G	110V	Working	Jeff Eck	manual
	4.5" Angle Grinder	Chicago Electric	91223	110	Working	Gavin Rondeau	File:ANGLE GRINDER.pdf
	Combo Shear/Brake/Roller	Central Machinery	5907	Working	Working	Gavin Rondeau	File:SHEAR-BRAKE-ROLLER.pdf
	Horizontal/Vertical Metal Cutting Band Saw	Central Machinery	93762	110	Working	Gavin Rondeau	File:LAYDOWN BANDSAW.pdf
	14" Vertical Metal/Wood Cutting Band Saw	Jet	JBS-14MW	110	Working	Gavin Rondeau	File:Jet JBS-14MW manual.pdf
	1/2" Bandfile Belt Sander	Chicago Electric	92158	110	Working	Gavin Rondeau	File:BANDFILE.pdf
	Bar and Rod Bender	Central Machinery	38471	Elbow grease	To Setup	Gavin Rondeau	File:BAR AND ROD BENDER.pdf
	Tubing Roller	Pittsburgh	99736	Working	Setup	Gavin Rondeau	File:99736 tube roller manual.pdf
	20 Ton Hydraulic Press	Central Machinery	20 Ton	Working	Setup	Gavin Rondeau
	1000lb Hydraulic Lift Table	Central Machinery	1000 lbs, 34" max height	Working	Setup	Gavin Rondeau	File:Lift table manual.pdf
	Foldable 2 Ton Shop Crane (Cherry Picker)	Pittsburgh	2 Ton	Working	Setup	Gavin Rondeau	File:Shop Crane manual.pdf
	120K BTU/hr Gas Forge	Johnson Forge	120K BTU	Needs converted to NG	Setup for propane	Gavin Rondeau
	Anvil	Trenton	Made in 1900	On the Stump	Setup	Gavin Rondeau

Metal Shop Classes

Safety Class

• This is a free course for members
• This class covers the basic safety knowledge to allow members to use the basic metal working tools and grants access to the basic equipment.
• It does NOT teach members how to properly use these tools.
• It does NOT unlock machining tools, Tormach, mill or lathe.
• It does NOT unlock welder or plasma cutter.
• It does NOT unlock Forge or smelting equipment.
• If you are not sure how to use a piece of equipment needed for your project ask someone that knows or the BD or assistant BD.
• If you are uncomfortable with using multiple pieces of equipment then take the Intro to Metal Shop class, which will teach you how to operate the basic tools and allow you to get hands on with them with supervision.

Intro to Metal Shop

• We are currently working on this class and is not quite ready to be offered yet.
• We are going to try to make this class also cover the safety class requirements soyou donthave to take both.
• If you have not been around metal shops before or don't know how to use the equipment this is the class for you!
• This class will offer members a chance to learn how to USE the basic metal working tools in the metal shop.
• It will cover safety, setup, blade changes, adjustments and basic use of all the basic tools. Including but not limited to files, hand grinders, hand drills, drill press, horizontal and vertical band saws ,bench grinders and whatever else we time to cover.
• There will be a fee for this class.

MIG Welding Class

• Never welded before? Want to improve your welding abilities? Here you go!
• Class starts with some short videos and some classroom time, then moves out to the metal shop for an equipment overview and demonstration. After that, every person will have a chance to do some welding with and experienced welder coaching you.

Plamsa Cutting Class

• There will be a fee for this class.
• Short class time to learn some basics
• This class will cover cutting steel with the plasma cutter and what settings to use for what thickness of metal. Proper tip selection and changing. It will also have a hands on session where everyone will get a chance to use the cutter on different thickness materials.

Milling Class

• We are currently looking for an instructor for this class, if you are interested in teaching this class contact metal shop BD, please.

Lathe Class

• We are currently looking for an instructor for this class, if you are interested in teaching this class contact metal shop BD, please.

Bicycle Maintenance

• We are currently looking for an instructor for this class, if you are interested in teaching this class contact metal shop BD, please.

Basic Forge Techniques

• We are currently looking for an instructor for this class, if you are interested in teaching this class contact metal shop BD, please.

Metal Shop Certified Members

Name	Certification Date	Notes
Jason Bailey	1/16/16
Catherine Barba-Abay	1/16/16
Bryan Barr	1/16/16
William Davisson	1/16/16
Alex Gretsky	1/16/16
Jim Hammer	1/16/16
Nathan Huff	1/16/16
Mike Hutton	1/16/16
Christian Kindel	1/16/16
Geoff Kisch	1/16/16
Jeremiah Loder	1/16/16
Logan Pajunen	1/16/16
Dustin Richey	1/16/16
Samuel Schurter	1/16/16
Stuart Smith	1/16/16
Joshua Soutiere	1/16/16
David Springs	1/16/16
Paul Wilson	1/16/16
Tyler Ball	1/23/16
Jerry Carpenter	1/23/16
Charlie Fair	1/23/16
Curt Gridley	1/23/16
Cory Kertz	1/23/16
Eric Lamp	1/23/16
Marcus Mosley	1/23/16
Keith Rowley	1/23/16
Charles Timmons	1/23/16
W C Vice	1/23/16
Matthew Warren	1/23/16
Michael James	1/28/16
Jesse Lee	1/28/16
Joseph Lobdell	1/28/16
Samuel Mcconnell	1/28/16
Aaron Rivers	1/28/16
Steve Saner	1/28/16
Brad Cooley	1/30/16
Ed Hutson	1/30/16
Bryant Ketchersid	1/30/16
Barry Wright	1/30/16