Metalworking stations for woodworkers - thoughts and experiences

[Kev]

Hi All,

I suppose the majority focus here is woodwork, but there's been evidence of some very skilled metal workers on this forum, from fusion projects that integrate steel and timber through to tools and accessories machined (as either prototypes or finished goods). A serious metalworking shop is obviously going to have lathes and mills and MIG,TIG,ARC nasties, CNC doodads, etc  ... and that's ignoring the possibilities of forges and the like. Far more than the likes of the average woodworker. Plus I can't imagine welding something in a tinderbox of wood chips and sawdust [eek]

Anyway, I was hoping people could share their compact metalworking station ideas or actual work centres. Apart from a bench with a bench grinder and a Tormek (all for sharpening), I have nothing else - but I'd like to be able to fabricate metal or aluminium "stuff".

Walk away, get it done professionally, do a course before you even think about it, etc are all obvious immediate responses - but let's assume we want to make a couple of metal brackets and spray paint them, or fabricate a chassis for an electric go-cart, make a frame for a rustic coffee table, etc.

Please share [wink]

cheers,

Kev.

 

[sgryd]

I have an outside bench for welding and heavy duty work. Inside I have a small metal lathe (too small). I was very close to push the button on a Sieg X3 mill (www.arceurotrade.co.uk). But lately I've been watching YouTube videos on Heiz High Z CNC router. This puppy will do what I need in aluminium AND wood. I'm hoping I can get the High Z T1000 in a couple of months.

I wouldn't do welding in my shop. Very special care should be taken before doing hot work inside.

//Michael

 

[wow]

First, as mentioned above, you're going to want a separated area for metalworking. It doesn't have to be totally dedicated to metalworking, but it does need to be able to be isolated pretty well from your woodworking area. I have my metalworking and vehicle maintenance areas in the same space, since they are largely compatible. Just remember that metalworking is DIRTY no matter how careful you are.

Regardless of what projects you undertake, I think you'll want or need the following:

• A good heavy-duty metalworking vise. This should have 5-6" (125-150mm) wide jaws. You'll also need a good, heavy bench to mount it on.

• A drill press. This can do double-duty, i.e wood and metal, as long as you clean it up well between uses.

• Several grinders - at least one bench grinder (6"/150mm minimum), and mutliple portable ones so you can keep grinding discs on one, cut-off discs on another, flap sander on a third, etc.

• A good welder. Buy once, cry once ... just like Festool.

• A metal-cutting bandsaw, either stationary or portable (Portaband style). This needs to be dedicated so you can keep the metal flecks, specks, and shavings out of your wood finishes, as that can REALLY mess them up. Ask me how I know?

• Steel welding/assembly table.

Later:

• Metal lathe or mill

I don't know what brand welders you have over there, but the big two here are Miller and Lincoln. My cousin is a professional welder and is partial to Miller so that's what I have. They (Miller) have an excellent forum - unfortunately nowhere near as good as the FOG - but they have lots of member projects and tips and stuff. Just like brad 'F' you can join without owning any of their equipment.

Hope that helps get you start?

 

[johninthecamper]

welding
electricity is easier to use once understood.
I would never give up my oxygen/ acetylene rig which is much easier to learn and it cuts

 

[wow]

I forgot to add a plasma cutter to the list. Addictive, fun, and very, very handy.

 

[Timtool]

I also have my metalworking place completely separated from the woodworking area, together with the general maintenance stuff for the car and other vehicles.
In the beginning i mixed the activities in the same location, but metalworking gets everything (including yourself) very dirty and covered in shavings and grease, everything that is completely incompatible with woodworking. I even have a drill press for wood, and another for metal.

My list is similar to the ones above:

-welder, semi auto or electrodes, semi auto is more practical but we worked years with electrodes (and i still prefer it) and built some heavy machinery with it. Electrodes work outside as well were the semi auto welder needs zero wind to work, not suited for reparation work in the field or outside.

- a bench grinder is practical but a small disk cutter will do as well.

- welding table, a nice first project. A full metal table on which you connect the welder so you can weld without having to put the power clamp on the workpiece.

- metal band saw, indispensable if you want to make things of any precision, we have a water cooled floor model. the day we purchased that thing the quality and possibilities of what we could make got multiplied big time.

- drill press, drilling in metal requires more guts than in wood, 20mm drill capacity is a minimum.

 

[rmwarren]

Kev,

I did a ton of metal working ~30 years ago before getting more into woodworking. Mostly stuff like utility trailers, I probably built 15-20 of them while in my 20's. Had to dispose of that shop equipment when I moved from Nevada to the east coast. About 7-8 years ago I started dabbling in machinist-type work, i.e lathes/mills, etc. There's is a bit of overlap but very different requirements.

In the first phase I got by with a metal work table w/ a vice, a 220V MIG welder, oxy/acetylene rig, 4" angle grinder, abrasive chop saw and a bunch of Irwin vice grip type C clamps. There was not much I could not do with that limited gear, plus more conventional stuff like a drill, taps, wrenches, etc.

Once into smaller, more precision work the requirements skyrocketed. Small mill/lathe, calipers, vises, myriad setup aids, on and on. Seemed like everything I tried needed some other gadget to achieve the precision or result I was looking for. Now I am teetering on the edge of CNC to increase capabilities/speed.

Sounds like what you are looking for falls more into the first category. knowing what I now know, I would recommend:

• Carbide cutoff saw, in lieu of an abrasive saw
• 4.5" angle grinder
• Portaband, with a stationary base like the once from Swag Offroad - this is a nice-to-have item
• C-type vice grip clamps
• Bench vise
• A basic Oxy/Acetylene setup

The big choice will be what welder to get. If you go with MIG, avoid 110V, they are too limited. My first rig was a Millermatic 175, bought used form a welding shop. That machine would handle from 10Ga to 1/4" easily in one pass, and thinner/thicker material with some fiddling. I don't have any hands on experience but you may want to take a hard look at a good TIG setup, since you can weld AL & stainless with less hassle.

You first project will probably be building your work table, using angle and tube. Take pains to make sure it is square and plumb, since you will be clamping everything to it on your later projects. 

Have fun!

RMW

 

[CarolinaNomad]

[popcorn]

 

[teocaf]

i use a heavy duty hydraulic table on wheels i got  from Grainger.  It's been invaluable for adjusting working height when working/welding with heavy materials, as well as for loading/unloading materials into the shop.  in my metalworking area, i also use a high temp welding curtain on one side so that i can limit the spark reach when welding and plasma cutting, and on the other side against the wall i screwed thin gauge galvanized metal sheets