Difference between revisions of "Metalshop Area"

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| [[File:ANGLE GRINDER.jpg|200px]] || 4.5" Angle Grinder || Chicago Electric || 91223 || 110 || Working || [[User:Gavin Rondeau|Gavin Rondeau]] ||[[File:ANGLE_GRINDER.pdf|manual]]
 
| [[File:ANGLE GRINDER.jpg|200px]] || 4.5" Angle Grinder || Chicago Electric || 91223 || 110 || Working || [[User:Gavin Rondeau|Gavin Rondeau]] ||[[File:ANGLE_GRINDER.pdf|manual]]
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| [[File:SHEAR-BRAKE-ROLLER.jpg|200px]] || Combo Shear/Brake/Roller || Central Machinery || 5907 || Working || Working || [[User:Gavin Rondeau|Gavin Rondeau]] ||  

Revision as of 21:02, 24 October 2016


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!!
  • 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.

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.

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
Tormach PCNC 1100 Series3.jpg 4 Axis 34" x 9.5" Tormach CNC Mill Tormach PCNC 1100 220 Working Curt Gridley [manual]
Anatomy of Logan Lathe.png 12"x 35" Metal Gear Head Lathe Logan-Powermatic 2557TH 220 Working ?? File:Logan manual.pdf
Craftsman lathe.jpg 12" Metal Lathe Craftsman 101.28990 110 Working ?? File:Craftsman Lathe manual.pdf
Miller211.jpg MIG Autoset Welder Miller Millermatic 211 Autoset 220 Working Jeff Eck File:Miller211 manual.pdf
Hypertherm30XP.jpg Plasma Cutter Hypertherm 30 XP 220 Working Jeff Eck File:Hypertherm30XP manual.pdf
WELDING HELMET.jpg Welding Helmet Chicago Electric 91214 solar Working Gavin Rondeau File:WELDING HELMET.pdf
DWE402G.jpg 4-1/2” Paddle Angle Grinder DeWalt DWE402G 110V Working Jeff Eck manual
ANGLE GRINDER.jpg 4.5" Angle Grinder Chicago Electric 91223 110 Working Gavin Rondeau File:ANGLE GRINDER.pdf
Tumbler.jpg 18 Lb Vibratory Tumbler Chicago Electric 96923 110 Working Gavin Rondeau File:Tumbler manual.pdf
SHEAR-BRAKE-ROLLER.jpg Combo Shear/Brake/Roller Central Machinery 5907 Working Working Gavin Rondeau

File:SHEAR-BRAKE-ROLLER.pdf

BANDSAW.jpg Horizontal/Vertical Metal Cutting Band Saw Central Machinery 93762 110 Working Gavin Rondeau File:LAYDOWN BANDSAW.pdf
Jet JBS-14MW photo.jpg 14" Vertical Metal/Wood Cutting Band Saw Jet JBS-14MW 110 Working Gavin Rondeau File:Jet JBS-14MW manual.pdf
BANDFILE.jpg 1/2" Bandfile Belt Sander Chicago Electric 92158 110 Working Gavin Rondeau File:BANDFILE.pdf
BAR AND ROD BENDER.jpg Bar and Rod Bender Central Machinery 38471 Elbow grease To Setup Gavin Rondeau File:BAR AND ROD BENDER.pdf
Tube roller.jpg Tubing Roller Pittsburgh 99736 Working Setup Gavin Rondeau File:99736 tube roller manual.pdf
20ton press.jpg 20 Ton Hydraulic Press Central Machinery 20 Ton Working Setup Gavin Rondeau
Lift Table.jpg 1000lb Hydraulic Lift Table Central Machinery 1000 lbs, 34" max height Working Setup Gavin Rondeau File:Lift table manual.pdf
Foldable Shop Crane.jpg Foldable 2 Ton Shop Crane (Cherry Picker) Pittsburgh 2 Ton Working Setup Gavin Rondeau File:Shop Crane manual.pdf
Johnson forge.jpg 120K BTU/hr Gas Forge Johnson Forge 120K BTU Needs converted to NG Setup for propane Gavin Rondeau
ANVIL.jpg 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 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 an 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 Authorized Members

Name Certification Date Notes
Jeff Eck 1/16/16 Welding Dude
Mike Barushok 1/16/16
Rustin Atkeisson 1/16/16
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 Tormach dude
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
Clark Shultz 1/28/16 Safety Sultan
Brad Cooley 1/30/16
Ed Hutson 1/30/16
Bryant Ketchersid 1/30/16
Barry Wright 1/30/16
Johanna Mittman 1/30/16
Dean Day 4/15/16
Todd Grant 4/15/16
Christy Bennett 4/15/16
Jason Becker 4/15/16
Matt Cannon 4/15/16
Dana Danaver 4/15/16
Pal Poirier 4/15/16
Ernest Sharp 4/15/16
Eric Sommer 4/15/16
Rose Hansen 4/15/16
Robert Shultz 4/15/16
Joseph Woodridge 4/15/16
Joe Groom 4/15/16
Matt Pewewardy 4/15/16
Travis Kvassay 4/25/16
James Lancaster 4/25/16
Michael Conkling 4/25/16
Steve Owens 4/25/16
Connor Turley 4/25/16
Tobias Digennaro 4/25/16
Bob Jackson 4/25/16
Larry Frank 5/6/16
Andrew Shaw 5/6/16
Resha Parajuli 5/6/16
Terry Powell 5/6/16
Paul Sheets 5/6/16
Jerry Shubert 5/6/16
Austin White 5/6/16
Larry Roth 5/6/16
Chris Strait 5/6/16
Tom McGuire 6/11/16
Alexander Melton 6/11/16
Kyrail Williams 6/11/16
James Classen 6/11/16
Robert Jackson 6/11/16
Michael Piccone 6/11/16 -
Henry Gridley 6/11/16
William Parsons 6/11/16
Jerry Stewart 7/18/16
Blake Baysinger 7/18/16
Dale Morrow 7/18/16
John Harrison 8/15/16
Penny Kralicek 7/18/16
Bob Kralicek 7/18/16
Mike Brennison 7/18/16
Thomas Bloom 7/18/16
James Tennant 7/18/16
Susan de Wit 7/18/16 Ceramics BD
Mark Esau 7/18/16
James Dorsch 7/18/16
Kip Landwehr 8/15/16
Alez Kotten 8/15/16
Jeremiah Burian 8/8/16