Metalshop Area

General Information

MakeICT's metal shop is an open 1200 sq ft area dedicated to metal working with a shared space for bicycle repair.

Jeremiah Burian is the Metalshop Lead. David Springs, Brian Groom Michael James and Paul Maseberg are assistant Leads.

Machine Access Policy

• Use of the Metal Shop requires attendance in the area-specific safety class. Completion of the safety class will grant access to the area and use of the basic tools.
• Advanced tools require demonstration of safe and correct operation to an approved authorizer, as listed on the Wiki, or attendance in an instructional class. These tools are: Welders, Plasma Cutter, Forge, Lathes, Manual Mill, CNC Plasma, Powder coating equipment, Oxy / Acetylene torch, and the Tormach CNC Mill.

Approved by the board on January 18, 2018

General Shop Safety

1. Do not use any equipment 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. unplug The equipment,leave a note on the machine and notify the metalshop Lead-Jeremiah Burian.
3. Always check tools prior to use.
4. Wear safety glasses at all times when tools are in use in the shop area.
5. Ear protection is recommended
6. No open-toed shoes or loose clothing
7. Remove objects on hands and wrists
8. Remove dangly necklaces and earrings
9. Restrain long hair to prevent entanglement
10. Do not leave machines running unattended.
11. 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.
12. Be aware of the work going on around you.
13. Wear proper PPE (personal protective equipment) Safety glasses welding sleeves, grinding shields etc.

Metalshop Safety

1. 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.
2. Users who consistently fail in their clean-up responsibilities may be denied shop access.
3. Make sure machines are in the “off” position and motion has stopped, before leaving them after use.
4. Make sure all gas cylinders are in the off position while not in use.
5. 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.
6. Use equipment only for its intended use.
7. If you have made an adjustment to a piece of equipment, return it to its normal position after you are done.
8. All guests are the responsibility of the member. Guests are NOT allowed to use equipment. Children under 8 years old are not allowed for safety.

Machine shop Specific Safety

1. This includes all mills and lathes in the metalshop.
2. Lead or authorized peer certification is required to operate this equipment. This can be as easy as showing the Lead 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.

Welding shop Specific Safety

1. Use the proper face shield when grinding and a welding helmet when welding.
2. Closed-toed shoes.
3. Wear the appropriate glove while welding.
4. We suggest you wear ear protection to prevent sparks from entering your ear canal.
5. 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.
6. 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.

Burns

1. Welded metal will remain hot for several minutes after it is welded.

UV Burns

1. The light emitted from a weld arc is brighter than the sun. Do not look at the arc without wearing a full-faced welding mask with a shade 9 or darker filter plate.

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" Tormach CNC Mill	Tormach	PCNC 1100	220	Working	Curt Gridley	[manual]
	3 Axis 48" x 48" CNCPlasmasCutter	MakeICT	N/A	220	Working	Curt Gridley	TODO
	12"x 35" Metal Gear Head Lathe	Logan-Powermatic	2557TH	220	Working	Joe Groom	manual
	12" Metal Lathe	Craftsman	101.28990	110	Working	Joe Groom	manual
	8"x29" Mill Drill	Enco	GL-30B	110	Working	??	manual
	MIG Autoset Welder	Miller	Millermatic 211 Autoset	220	Working	Jeremiah Burian	manual
	MIG Welder	Hot Max	135WFG 135 Amp	110	Working	Jeremiah Burian	TODO
	CNC Plasma Table Cutter	Hypertherm	Powermax 65	220 3PH	Working	Jeremiah Burian	manual
	Plasma Cutter	Hypertherm	30 XP	220	Working	Jeff Eck	manual
	Welding Helmet	Chicago Electric	91214	solar	Working	Jeremiah Burian	manual
	5HP 60 gal Compressor	Ingersoll Rand	SS5L5	220	Operational	Jeremiah Burian
	4-1/2” Paddle Angle Grinder	DeWalt	DWE402G	110V	Working	Jeff Eck	manual
	4.5" Angle Grinder	Chicago Electric	91223	110	Working	Jeremiah Burian	manual
	18 Lb Vibratory Tumbler	Chicago Electric	96923	110	Working	Jeremiah Burian	manual
	Combo Shear/Brake/Roller	Central Machinery	5907	Working	Working	Jeremiah Burian	manual
	Horizontal Metal Cutting Band Saw	Grizzly	G0561	110	Ordered	Jeremiah Burian	manual
	Horizontal Metal Cutting Band Saw	Central Machinery	93762	110	Working	Jeremiah Burian	manual
	Tube Notcher	Baileigh	TN-250	-	Need Setup	Jeremiah Burian	manual
	1/2" Bandfile Belt Sander	Chicago Electric	92158	110	Working	Jeremiah Burian	manual
	Bar and Rod Bender	Central Machinery	38471	Elbow grease	To Setup	Jeremiah Burian	manual
	Tubing Roller	Pittsburgh	99736	Working	Setup	Jeremiah Burian	manual
	20 Ton Hydraulic Press	Central Machinery	20 Ton	Working	Setup	Jeremiah Burian
	1000lb Hydraulic Lift Table	Central Machinery	1000 lbs, 34" max height	Working	Setup	Jeremiah Burian	manual
	Foldable 2 Ton Shop Crane (Cherry Picker)	Pittsburgh	2 Ton	Working	Setup	Jeremiah Burian	manual
	Anvil	Trenton	Made in 1900	On the Stump	Setup	Jeremiah Burian

MetalShop 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.
• It does not unlock the welders or Plasma cutter.

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. There will be a fee for this class. Please wear appropriate footwear and long sleeve shirt.

Plasma 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. Please wear appropriate footwear and long sleeve shirt.

Tig Welding Class

• There will be a fee for this class.
• Small class size gives more one on one time to learn and practice welds.
• Class will cover safety, overview of Tig welder, Demonstration of both Aluminum and Steel welding, and provide each participant the opportunity to weld both types.

Milling Class

• We are currently looking for an instructor for this class, if you are interested in teaching this class contact the metalshop Lead

Lathe Class

• Classes are currently on the calendar.

Bicycle Maintenance

• We are currently looking for an instructor for this class, if you are interested in teaching this class contact the metalshop Lead

Basic Forge Techniques

• We are currently looking for an instructor for this class, if you are interested in teaching this class contact the metalshop Lead

MetalShop Wish List

A list of equipment or tools that the metalshop would like to obtain. If you would like to donate one of these tools please contact the Metalshop Lead before dropping the tools or equipment off.

1. Bandsaw : Grizzly G0561 - 7" x 12" Metal Cutting Bandsaw http://www.grizzly.com/products/7-x-12-Metal-Cutting-Bandsaw/G0561?utm_campaign=zPage&utm_source=grizzly.com
2. English wheel : Grizzly T25101 - Benchtop English Wheel http://www.grizzly.com/products/Benchtop-English-Wheel/T25101?utm_campaign=zPage&utm_source=grizzly.com
3. Shear :
4. Brake :
5. Finger brake :
6. Powder coating : Would need larger building for this
7. Large sand blast cabinet :
8. 2nd large compressor : 60 gallon plus. true 5hp or greater
9. Spot welder :
10. Iron worker : 50 ton ?
11. Jig table for welding :
12. Large manual mill with readout :
13. Hand tools / tool sets , ratchets, sockets, pliers, screwdrivers, cutters etc
14. Metal ring roller :
15. Tubing bender with hydraulics :
16. 2nd miller 211 welder :
17. Cnc lathe :
18. Sheet metal punch :
19. Power hammer blacksmith :
20. Paint booth : Would need larger building for this
21. More hand grinders :
22. Safety gear :
23. Safety Glasses:
24. Hearing protection : over the ear or in the ear
25. New welding hoods :
26. Replacement lenses for welding hoods :
27. Welding wire and consumables :
28. Material for plasma/welding etc :
29. Gate for garage door :
30. Bike parking area :
31. Knife maker belt sander : *2x72 Belt Grinder
32. Few more forges and anvils :
33. Swage blocks and tongs for blacksmith :
34. Welding gear: Welding curtains, welding sleeves, leather aprons, etc.