Metalshop Area
From MakeICT Wiki
Contents
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
- 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.
- 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.
- NEVER ASSUME A TOOL IS PROPERLY ADJUSTED. Always check the tool prior to use.
- Wear safety glasses at all times when tools are in use in the shop area.
- Ear protection is also recommended, many of the tools operate above 90 decibels and without protection, you are losing hearing.
- 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.
- Do not leave machines running unattended.
- 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.
- 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.
- 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
- 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.
- 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.
- Do not lean or sit on machinery.
- 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.
- Users who consistently fail in their clean-up responsibilities may be denied shop access.
- Make sure machines are in the “off” position and motion has stopped, before leaving them after use.
- Make sure all gas cylinders are in the off position while not in use.
- 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.
- Use equipment only for its intended use.
- If you have made an adjustment to a piece of equipment, return it to its normal position after you are done.
- Make sure the machine’s work surface is unobstructed and clean before use.
- Always be aware of the proximity of moving machine parts to body parts - fingers.
- Metal can be hot even though it doesn't look like it, beware of burns.
- Metal is heavy and can cause injury if falling.
- 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
- This includes all mills and lathes in the metalshop.
- 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.
- Due to the high level of technical understanding and cost of the Tormach CNC mill, extensive training will be required before use.
- All work shall be secured properly and all loose objects removed from tables before machines are operated.
- Milling cutters and other hardened tools shall not be struck with steel hammer. Blocks of wood, rawhide, or copper hammers should be used.
- Proper feeds and speeds shall be selected before operations are started.
- Machines shall be stopped before any attempts are made to measure or to check work.
- Guards and baffles shall be used to protect others from flying chips, oil or coolants.
- Most all equipment has pinch point or crushing areas that you need to be familiar with before using that equipment.
Welding shop Specific Safety
- Member is responsible for using welding curtains to protect other people in area from weld flash hazards.
- ALWAYS wear a proper face shield when grinding and a welding helmet when welding.
- ALWAYS wear closed-toed shoes, no excuses!
- It will make you more comfortable to wear a long-sleeved, non-flammable shirt such as a welding jacket while welding.
- Wear the appropriate glove while welding.
- 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
- 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.
- 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
- 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
- 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.
- There is little risk of fatal electrocution from a properly working MIG weld machine.
Burns
- 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.
- MIG welding steel will create sparks, so earplugs and full coverage safety glasses should be worn to prevent burns to sensitive tissue.
- 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.
- 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
- 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
- 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.
- 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.
- Storing
Equipment List
| Picture | What | Manufacturer | Model | Power | Status | Expert | How To |
|---|---|---|---|---|---|---|---|
 |
4 Axis 34" x 9.5" Tormach 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 | |
 |
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 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.
