Setting up a home metal workshop

For the last couple of years, have been going to a local Men's Shed to build the trike prototypes. Which is fine, but construction proceeds at a glacial pace. Members of the Men's Shed can work on individual projects, but that is secondary to the main purpose of the shed, which is for mostly-elderly men to socialize. In between the cups of tea and chatting with the guys, and very limited opening hours, only a very small amount of work gets done each visit. Also, they are currently only opening 4 days a week.

Really do want the trike project to progress faster, so have been gradually buying equipment to set up at home. I used to have a place in the country, with heaps of space, see this photo taken in 2003:

These days, though, the domicile is an apartment in outer suburbia, with a small courtyard in the back. It has two small garden sheds; here is one of them:

...not much room for setting up a metal workshop! The other shed has a workbench and lots of shelving. The one in the above photo, decided will be the main guy for the metalwork. Notice the bench frame on the left of the photo, and a hole in the side of the shed -- this is for feeding in steel or aluminium extrusion to a cutoff wheel. So, here is the inside:

...those benches are making use of what I already have. The pink one is a folding camping table, with chipboard on top.

The main items of gear in the above photo, are the cutoff saw, drill press, bench vice, and drill press vice. This is all hobby gear, fairly inexpensive, purchased from here:

Metal cutoff saw
https://www.bunnings.com.au/ozito-2300w-356mm-corded-metal-cut-off-saw-mcs-2355_p6290607

Drill press
https://www.bunnings.com.au/ozito-450w-corded-drill-press_p0412276

Not in the above picture, but an angle grinder is also essential. I bought the cheapest from Bunnings:

Angle grinder
https://www.bunnings.com.au/xu1-500w-100mm-angle-grinder_p0011397

...I purchased these items gradually over the last six months, and notice the prices have crept up since.

The two vices are from eBay:

125mm bench vice
https://www.ebay.com.au/itm/316029906878

Drill press vice
https://www.ebay.com.au/itm/166726440392

Will probably not screw the bench vice onto that table, as may want to move it around.

The Men's Shed has a metal bandsaw, which is very nice for cutting lengths of steel and aluminium. They also have a cutoff saw, like mine, but more hefty, more professional. However, the cutoff saw does a very rough job; lots of heat, poor quality cut.  The reason, is the cheap particle-disc. This video shows the incredible difference having a good saw disc can make:

https://www.youtube.com/watch?v=Z7kX7pqaFmI

Checked out these higher quality discs at Bunnings; however, have ordered one from AliExpress, which, as far as I can make out, is just as good, yet less than half the price. Have ordered a carbide disc, 305mm diameter, 25.4mm arbor (1 inch hole diameter) and 80T (80 teeth).

I have a stick welder, and after experience with welding inside and outside, the latter is preferable, as the high ambient light makes it easier to see the work piece through the welding helmet.

Yes, it is an automatic helmet, that becomes dark when the bright welding light reaches it; however, I found it easier to see the work when there is a high ambience beforehand. I think maybe, the automatic window becomes a little bit darkened in bright sunlight, to which the eyes adjust; so when the weld flame starts it is easier to see.

Also, welding emits noxious fumes, so definitely safer outside.

The intention is to buy some sheet steel and put it on the bench frame on the left of the second-from-top photo above. Which will probably need a tarp over it to minimize rusting.

I am posting this information so that anyone else who might want to build a trike like mine, or something else, will have some guidance as to the minimum gear to do effective metalwork.

Especially if you are space-constrained like me; it can be done! A practical detail about the sheds; as they are sitting on paving slabs, to minimize dampness in winter, I spread plastic sheet over the slabs, with a rubber mat on top. Cloth draped over the equipment also protects them from dampness. Dampness will be a major issue in some climates; where I am is a fairly dry Mediterranean climate.   

Tags: light