Table of Contents

Sheet Metals Clearance

Members who are already proficient in the subject matter may apply to receive a clearance by demonstrating a core set of skills and knowledge that allow them to safely and effectively use the equipment.

Most tools in the shop require clearance before solo use. Each tool is different and most are expensive and/or delicate.

During a Proficiency Based Clearance Instructors will provide Protohaven specific customs and rules for the equipment but will not provide technical instruction on the operation of the hardware, or software.

If a member needs to gain additional knowledge or skill they should take a Basic Skills Class to learn the required skills.

The items that will need to be demonstrated to gain the Proficiency Based Clearance are:

General Shop Rules

Be safe

  • Understands safety clearances are required as bare minimum.
  • Understands equipment must never be left unattended.
  • Understands why equipment must be reset after use.

Take care of the tools

  • Will not alter or use equipment beyond limits.
  • Will notify when maintenance is needed.

Keep the shop clean

  • Understands importance of cleaning up after oneself.
  • Will return borrowed tools to original location.
  • Understands anything left outside of your paid monthly or overnight storage may be removed and disposed.

Personal Protective Equipment

  • Knows whether synthetic materials may be worn during use.
  • Knows whether long sleeves can be worn beyond elbows during operation of equipment.
  • Knows whether loose clothing & hair may be worn down.
  • Knows whether open-toed shoes may be worn.
  • Knows whether safety glasses and hearing protection are required during operation.
  • Knows whether safety glasses are required when near someone else operating equipment in the workshop.
  • Knows whether additional PPE is required (e.g. apron, face shield…)

Area Specific Instruction

Identify & mitigate common hazards

  • Sharp things - shear blades and punches
  • Crushing hazard - no loose articles on the body, sleeves, gloves, or hand decorations (e.g. bracelets/rings)

Allowable Materials

  • Acknowledges use of only 16ga or thinner mild or annealed steel, aluminum, softer metals and plastics
  • Never cut or bend on nitrides created from plasma cutting

Shear

Point out the following tool features

TODO

Identify & mitigate common hazards

TODO

Allowable Materials

TODO

Safe Setup/Operation/Cleanup

TODO

Knowledge and Technique

TODO

Notes

  • check your sleeves & loose fabric - bad!
  • Don't do rod or tubing. Sheet metal 16ga only
  • Blue bar is emergency stop, works in either direction
  • Lower idler roll in the back with the black handles - match sizes
  • Want metal going in and up, not digging in.
  • Back out both E stops (on machine and on pedestal)
  • Press power button, green light turns on
  • Make sure tension knobs on both sides are consistent - for top and bottom front roller
  • In/out step levers
  • Pull the lock on the right side of the top roll out to allow removing fully rounded pieces. Make sure to lock it afterwards!
  • Drill slip controler
  • Maintenance:
  • Every month - apply ways oil (from oil can resting on lathe) to metal bushings on idle roller. Spin the roller to make sure it moves freely

Slip Roll

Point out the following tool features

TODO

Identify & mitigate common hazards

TODO

Allowable Materials

TODO

Safe Setup/Operation/Cleanup

TODO

Knowledge and Technique

TODO

Notes

  • check your sleeves & loose fabric - bad!
  • Don't do rod or tubing. Sheet metal 16ga only
  • Blue bar is emergency stop, works in either direction
  • Lower idler roll in the back with the black handles - match sizes
  • Want metal going in and up, not digging in.
  • Back out both E stops (on machine and on pedestal)
  • Press power button, green light turns on
  • Make sure tension knobs on both sides are consistent - for top and bottom front roller
  • In/out step levers
  • Pull the lock on the right side of the top roll out to allow removing fully rounded pieces. Make sure to lock it afterwards!
  • Drill slip controler
  • Maintenance:
  • Every month - apply ways oil (from oil can resting on lathe) to metal bushings on idle roller. Spin the roller to make sure it moves freely

Shrinker/Stretcher

Point out the following tool features

TODO

Identify & mitigate common hazards

TODO

Allowable Materials

TODO

Safe Setup/Operation/Cleanup

TODO

Knowledge and Technique

TODO

Notes

  • Use for curving L channel, and shrinking ripples in metal that's bent into convex shapes
  • Make sure the guard around the front of the tool is pushed in enough that the top die doesn't wiggle around excessively

Hand Brake

Point out the following tool features

TODO

Identify & mitigate common hazards

TODO

Allowable Materials

TODO

Safe Setup/Operation/Cleanup

TODO

Knowledge and Technique

TODO

Notes

  • Make sure electrical stuff is clear - sometimes it gets hung over the brake
  • Handles on sides are for raising/lowering the fingers - the right one tends to slip, be careful
  • Red counterweight on left side helps balance the front lever action
  • Clamp fingers down onto piece using the levers, then lift the front handles to bend.
  • Careful when taking fingers off - they can chip and break
  • Why switch fingers? If you are making bends in different axes, would have space to keep the bent parts clear of fingers
  • Switching fingers
  • Place triangular piece of wood under the fingers to prevent them from falling
  • Place hand under finger to prevent the finger getting damaged
  • loosen with 6mm allen key
  • When inserting, push up to the top
  • Upgrades
  • Safety wired allen key onto the machine for changing the fingers
  • Triangular piece of wood to hold the fingers when changing them
  • Machine a shaft collar / stop thingy for the stop rod on the brake
  • (cosmetic) Sand blast and powder coat the counterweight rod
  • Replace handlebars (cracked / bent close to the machine)
  • Wooden caddy for brake fingers when not installed in the machine - an inverted crib so they stay secure and slide to a safe place
  • Maintenance
  • Ensure pins are in place on handle, plus some ways oil to lube the mechanism
  • Ask Cord - label the 2x4s at the finger brake with what they're for

Turret Punch

Point out the following tool features

TODO

Identify & mitigate common hazards

TODO

Allowable Materials

TODO

Safe Setup/Operation/Cleanup

TODO

Knowledge and Technique

TODO

Notes

  • Hole size gauge on the right side matches to pin names
  • Insert changing handle into square slots, push orange ball away to allow for movement. Make sure it locks into place, otherwise you'll damage the pin
  • Too close to an edge causes the sheet metal to buckle
  • Put in material, bring lever down
  • Upgrades
  • Hook for hanging the changing lever
  • Thick steel bolster plate with holes in it for preventing buckling on turret punch

Notcher

Point out the following tool features

TODO

Identify & mitigate common hazards

TODO

Allowable Materials

TODO

Safe Setup/Operation/Cleanup

TODO

Knowledge and Technique

TODO

Notes

  • Can use the hold downs to brace the sheet
  • Upgrades
  • Thumb/hand wheel for tightening the hold downs, plus a way to keep the bottom of the bolt from turning
  • Pull handle down, chunks the metal
  • Clean up underneath after
  • Upgrades
  • Find matching wing nuts for hold replacement down screws on notcher
  • Maintenance
  • Verify the shafts for the cam section are in place and not slipping out; add some ways oil