Metalshop Area
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Revision as of 23:53, 30 December 2016 by JeremiahBurian (talk | contribs) (→Machine shop Specific Safety)
Contents
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
Metal Shop 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.
- 2x72 Belt Grinder
- 12 inch Disc grinder / belt sander combo
- Tubing notcher
- Cordless power tool set
- Pneumatic nibblers and shears
- Manual mill endmills and bits
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 equipment 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. unplug The equipment,leave a note on the machine and notify the metalshop Lead-Jeremiah Burian.
- Always check tools prior to use.
- Wear safety glasses at all times when tools are in use in the shop area.
- Ear protection is recommended
- No open-toed shoes or loose clothing
- Remove objects on hands and wrists
- Remove dangly necklaces and earrings
- Restrain long hair to prevent entanglement
- 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.
- Wear proper PPE (personal protective equipment) Safety glasses welding sleeves, grinding shields etc.
Metalshop Safety
- 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.
- 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
- This includes all mills and lathes in the metalshop.
- 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.
- 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
- 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 | Working | ?? | File:Logan manual.pdf |
 |
12" Metal Lathe | Craftsman | 101.28990 | 110 | Working | ?? | File:Craftsman Lathe manual.pdf |
 |
8"x29" Mill Drill | Enco | GL-30B | 110 | Working | ?? | File:RF-30 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 |
 |
18 Lb Vibratory Tumbler | Chicago Electric | 96923 | 110 | Working | Gavin Rondeau | File:Tumbler manual.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 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.
