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Workshop Course Descriptions
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Workshop participants in the 4-day Metalworking
Intensive refine their skills on the English Wheel.
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All of our Metalworking Intensives cover a different fundamental training topic each day, and each day is a stand-alone intensive study and practice on that technique. You may attend all four days, or any combination of days that are areas you wish to study. However, priority is given to participants who plan to attend all four days.
Common topics -- such as planishing, metal finishing, annealing, work-hardening, heat-treating, patterns, and layout - will be covered in context on each of the four days.
A packet of special workshop preparation materials is sent to you three weeks prior to the workshop. It contains three videos, and many pages of printed material for your study prior to workshop attendance. This packet is available only to those who sign up for all four days of the workshop (and if available separately would be worth $200). If you are attending only part of a workshop, please contact us regarding what advance-study materials you will need.
Please note: Kent's tricky techniques for teaching include conundrums, brick-walls, and brain twisters. You will learn to solve problems and to think like a real metal-man -- by overcoming obstacles, and by using your bucket of grey cells. Gold star, anyone? It goes on your permanent record, you know.
"The Original" 4-Day Metalworking Intensive
All 2011 Dates are TBA.
Oct. 8, 9, 10, 11 - 2010
Day 1 - Stretching Tools & Methods
Fundamental concepts of metallurgy and metal behavior are introduced, so that the student is made familiar with (and can anticipate the response of) the metal to certain forces. Annealing, work hardening, and heat-treating are covered in context of both making and repairing parts. Many approaches to stretching problems are covered, enabling the student to easily create his own solutions to achieve many shapes and forms. You will understand how to avoid excessive thinning when achieving the fastest stretch possible. The Air Shaping Hammer and other rapid forming tools and methods are applied in context. Applications: bowls, hollows, reverses, fairings, saddles, and curved flanges.
Day 2 - Shrinking Tools & Methods
Using the Stretching class as a springboard to open students' minds, the Shrinking class strives for comprehension of the underlying relationship of the duality of metal; and how heat and cold, soft and hard, and thick and thin affect the ability of the metal to take a new shape. Kent has defined 14 separate and distinct methods to shrink sheet metal, decreasing the surface area by increasing its thickness. Most classes will cover 9 methods, and an occasional "eager and capable" class will absorb 12 of these concepts. You will understand how to efficiently and accurately shrink many metals by taking this 4-day course. Applications: Hollow shapes, curved flanges, making repairs and adjustments.
Day 3 - Aircraft Aluminum Gas Welding
Applications on non-structural parts and alloys are given in context. Using traditional proven teaching methods, each student is expected to make a good weld in 6 hours, just as the aircraft factories trained their welders years ago. Torch and tip selection, pressure regulator settings, fluxes, and fillers are covered in detail. Joint design, geometry, distortion, and applications are demonstrated and detailed. Students are given a basic joint to master and when done, they are encouraged to move onto a more difficult joint. Flux-cleanup, benefits and drawbacks of welding methods are contrasted thoroughly. 2 hours instruction, critiques, and demonstrations, with 6 hours of student hands-on practice.
Day 4 - Forming & Shaping Machines
The English Wheel, Pullmax, and the Air Shaping Hammer are shown in contrast to (and in support of) each other using demonstrations and projects. Much time will allow the student to become familiar with each machine, as the student prefers. Projects are very helpful for this segment.
Cost: $345 per day (includes breakfast, lunch, materials & supplies).
Pre-req: Sincere interest in metalworking and a willingness to get your hands dirty. This workshop is for all skill levels.
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Have you already been to "The Original" 4-day Intensive? Want some more challenge, inspiration, and intimidation? Read On...
4-Day Metalworking "More" Intensive
Oct. 22, 23, 24, 25 - 2010
Most of our students have asked for a follow-up course that goes more deeply into the topics offered during the Original 4-day Intensive. There will be an interesting class project in which students will contribute as their skills and individual interest inspires them. Credit for taking a previous Intensive is mentioned, and you are eligible for increased harassment during the Advanced portion.
Day 1 - Development
Developing patterns and determining contours using paper, tape, and other materials. Using various methods to transfer known locations and artwork to paper. Blanking the part. Using the mathematics of geometry to anticipate where and how much to shrink or stretch. Station Buck and Mock-up development and construction, using a variety of materials.
Day 2 - Beginning the shape, first things first
How to start the shaping process using rough and rapid stretching and shrinking, using flow-forming and hot working methods. "Torch-forming" applies here. Hammer-forming using the Little Power Hammer and Pullmax-forming also apply. Smoothing and planishing using both hand methods and Machines. English Wheel-forming will also be used, and also the planishing Wheel. Individual panels are brought to fit and finish during this day.
Day 3 - Joining
How little parts become big ones. Some parts just have to be made big, but others start small and then get joined together into larger ones. "A lot of forming and a little welding, or a little forming and a lot of welding." We go through the process of learning how to determine Large Panel forming, and Small Panel forming - and why things are the way they are. Butt Welding will be the order of the day, whether you are doing steel, copper, aluminum, or stainless. Be prepared to show your welding skills in public. Then, we have Problem Solving. I expect that nobody gets distortion, but IF it should creep in to your shop then here are ways to control or defeat Distortion.
Day 4 - Making the thing fit
Fitting is a whole craft/skill/art unto itself. Aircraft factories had "Fitters," men and women specifically trained to take the panel made in production and get it to fit onto the airplane. Auto factories also had fitters, just before the paint shops, where the final touches made the cars nicely fit. There are many tricks to get a good fit, especially after welding several panels together. I once helped a guy named Lindquist fab, assemble, fit, and planish the front end of a Cobra Daytona Coupe together, and that slide show is a good teaching aid.
Cost: $345 per day (includes breakfast, lunch, materials & supplies).
Pre-req: We highly recommend attending "The Original" 4-day Metalworking Intensive first. However, if you have extensive metalwork experience please contact us and we will discuss which course is best for your skill level.
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Steelworking Intensive
2011 Dates are TBA
Nov. 5, 6, 7, 8 - 2010
For those of you who are into automotive restoration as a profession or a hobby will be right at home with us for this workshop. Last year a customer brought with him the front fender to his 1958 Desoto which was damaged around the front headlight brawl when a patch wrongly welded in. The students helped as Kent showed them how to replace the entire front section and fit the patch to the headlights with nothing more than a few hand tools and a torch. After a few hours the seamless patch was finished! Car, Motorcycle, Air Plane or Boat, bring difficult part and let Kent show you how to get started!
Day 1 - Methods for repairs for rust and crash damage
Making rapid tooling for repair panel fabrication, and repairing damaged panels starts this 4 day event. Kent's years of doing steel body restoration with some of the masters of Rollover Repairs will bring a lot of light to this topic. Add in annealing and hardening and this day is packed.
Day 2 - Stretching, Shrinking, and Planishing
There are some rapid ways to shrink steel panels right on the car, bike, or haybaler, so let's get with the program and move some metal. The same goes for stretching to flare some fenders. And then smoothing…why not pick up a Fender Planishing machine and let the machine do it…right on the car. Ever heard of or seen The Amazing Shrink Disc? Or the whirling whanging rubagizmo? I can show you how the Texas dustbowl Depression-era metalmen lifted out hail dents without a sound.
Day 3 - Gas Welding, Brazing and Soldering
What really works and what is a time-waster? Why braze? How can solder save time? Is that gas welding faster than TIG? Is the MIG welder really a manure spreader? We take a close look at what is appropriate for the task. Chrome? No sweat. I have made a bunch of steel stuff for chrome-plate, and have done serious repairs for chrome. How do you prep? I worked with a plating shop for years…prepping for Pebble Beach. Want to win? I did and I can show you some pretty effective methods.
Day 4 - Oil cans
Need I say any more? I once spent 3 MONTHS on a fancy 5-piece brass-trimmed Pierce Arrow hood that had gone saddle-back after a load of snow fell on it. Then some character sandblasted it. I sure learned a lot about shrinking…and oil cans. What are oil cans (oilcanes?)? How do they form? You will be surprised to learn what the truth is. And how easy it can be to send one packing. You will make them, and erase them by days' end. And, if you are a real pro and get through my obstacle course…we can do a class on Louvers.
Cost: $345 per day (includes breakfast, lunch, materials & supplies).
Pre-req: Sincere interest and basic metalworking skills. ("The Original" 4-Day Intensive is NOT a pre-requisite for this class).
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Mastering the Torch
Welding, Brazing & Soldering
2011 Dates are TBA.
December 4, 5, 6, 7 - 2010
Here is your opportunity to learn how to join 5 different common metals 3 different ways, and how to apply this to fabrication and repairs. If you have been wanting to learn the advantages of torch welding (versatility, cost, efficiency, control), or if you are just wanting to improve your welding, brazing and soldering skills, this course is for you.
Day 1 - Torch Basics & Soldering steel, aluminum, stainless, copper, and brass.
We begin the first day with setting up the torch, regulators, and going over safety. Students then go on to define soldering and the temperatures involved. We experiment with cleaning the metals, choosing solders and fluxes, and practicing soldering techniques. Joint designs are then compared, along with tensile strengths and hardnesses.
Soldering for repairs, constructions and fabrication are covered in detail, and you will learn to join the different metals to each other and to themselves. Students are required to participate in several hours of hands-on practice.
Day 2 - Brazing steel, copper, aluminum, brass, 4130, and stainless.
We will discuss working temperatures, tensile strengths, and fluxes and fillers. We will distinguish clearly between soldering and brazing. Misinformation about "hot metal" joining is discussed thoroughly. Students will learn proper cleaning and joint prep, along with the techniques for setting the torch and applying different brazes. Several hours of hands-on practice is required of all students.
Day 3 - Welding steel, 4130, aluminum, and copper.
Students will learn the difference between welding, brazing, and soldering. We will use various joint designs and discuss pro's and con's of each. Students are expected to learn tensile strength variations between the methods, and several hours of student practice is required.
Day 4 - Practice makes perfect.
Since the amount of methods covered on previous days will require many hours of practice, this last day will make a big difference in your skill level. Students will practice more on the different techniques and correct any deficiencies. We will also cover joining techniques applicable for chrome plating.
Cost: $345 per day (includes breakfast, lunch, materials & supplies).
Pre-req: Sincere interest and basic metalworking skills. ("The Original" 4-Day Intensive is NOT a pre-requisite for this class).
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Tank Construction, Auto-Aircraft-Motorcycle-Other
All 2011 Dates are TBA.
Kent has been gathering tank construction methods for years. Making leak-proof tanks is basic, but making tanks of terne plate, aluminum, stainless, or copper requires some careful detail and planning. This 4 day workshop will cover the entire process of building a tank. First day will be spent in the drawing and planning stage, where seams, joints, baffles, and fittings will find proper location with respect to best function and manufacture. Paper and poster boards patterns will also be made. The second day will see blanks made and then form blocks for specific applications. Parts will be formed to match the overall plan. Third day is spent assembling the tank and forming all of the necessary pieces. The fourth day will involve tacking, welding, brazing, and soldering the tanks together. Metals involved may include aluminum, steel, and stainless.
Cost: $345 per day (includes breakfast, lunch, materials & supplies).
Pre-req: An understanding of shop environment, hand tools, and basic processes of measuring, marking, and cutting sheet metal. ("The Original" 4-Day Intensive is NOT a pre-requisite for this class).
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Louvers, Flow Forming, and a Project -
Building a Grille Shell for a Pre-war Alfa Romeo
2011 Dates are TBA.
Day 1–Louver secrets
Kent has compiled a number of ways to make louvers quickly and accurately. He has a louver punch with a high-tech set of spring-loaded louver dies. Using these and four more ways, you will learn five methods of making louvers. From using a press and precision-machined dies, to making your own dies with no machining, to making louvers either free-hand or with very basic forms, you will become a Louver King.
Day 2–Flow Forming
We all use a mallet or hammer to form parts, but there is a faster way that is incredible. Join us to have some real rapid fun. Students will develop an understanding for the tooling and force required for making parts using this method. Several form blocks will be provided for the class, and students are welcome to bring projects.
Day 3 and 4 – Project Time!
Learn how to build a grille shell for a Pre-war Alfa Romeo from start to finish
Cost: $345 per day (includes breakfast, lunch, materials & supplies).
Pre-req: Sincere interest and basic metalworking skills. ("The Original" 4-Day Intensive is NOT a pre-requisite for this class).
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Alaska Workshops
TM Technologies will be offering two workshops in Alaska for 2010. The first will be in Kenai on March 14, 15, 16 and will cover the Power Hammer, Pullmax and English Wheel The Second will be held in Anchorage where the first day will be on Steel Working and the Second Day will be on Aluminum. If you have any questions or you would like more detailed information please contact us at 530-292-3506.
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We Also Offer
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Getting Started in Metalworking
This course is specially designed for those just getting started in metalwork and for those wanting to learn how to handle the tools in the shop environment. Learn the hand techniques of shrinking and stretching, annealing, and joining. Learn about the seven main machines that form the metal: the shears, the brake, the Wheel, the Air Hammer, the Pullmax, the shrinker/stretchers, and the bead roller.
Day 1 - The tools & fundamentals of hand-forming metal
Class begins with a show and tell of many different hand tools used for straightening and fabricating sheet metal bodywork. Demonstrations of straightening and fab follow, using hammers, dollies, slappers, spoons, anvils, files, and sanding. Students are given projects for their own practice of these methods. Students will learn to form sheet metal into complex shapes, anneal the work-hardened metal, and cut and trim the metal. The oxy-acetylene torch will be introduced, along with proper setting and safety measures. Flow forming for hollow and reverse shapes will also be covered.
Day 2 - The basics of shrinking & Stretching
Students continue on with more hand tools, learning to both stretch and shrink with the same hand tools. Cutting, shearing, and proper deburring procedures will be learned. An introduction to paper patterns and layout will help students understand how to analyze solid geometry, and how to divide problems into bite-sized chunks. There will also be practice using seven different shrinking machines to make several compound shapes.
Day 3 - Welding, Brazing & Soldering
Welding, brazing, and soldering of aluminum sheet will be the main focus, with further emphasis on the oxy-acetylene torch. Flange joints, butt joints, radius joints, and lap joints will be used for the student's practice. There will be several hours of hands-on practice required. 99% of students learn to make a good weld on aluminum in this course.
Day 4 - Introduction to Metal Forming Machines
The day will begin with a thorough 2-hour module on the bead-roller, or "jenny" machine. Die design, application and problem-solving will be the key elements. Pre-stretching and other methods of solving panel-distortion problems will be covered. We will go on to do a module on the Wheel, with students learning proper setup, clearance, pressures, tracking patterns, and both hollow and reverse shapes. Students will be doing two hours of hands-on practice, solving problems and getting used to the flow of the machine. The Pullmax and Air Power Hammer are also introduced and used during this four day course.
Note: Students are given show-and-tell, lectures, demonstrations, and then hours of hands-on practice. All students are expected to participate fully in all phases of the class instruction. MERE SPECTATING IS NOT PERMITTED.
Cost: $345 per day (includes breakfast, lunch, materials & supplies).
Pre-req: Sincere interest and basic metalworking skills. This workshop is for all skill levels.
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Copperworking & Art Metal
We will begin by comparing copper to known/familiar metals, and then contrasting it by its working characteristics. Since this will be mostly for artists/artisans/sculptors our format will be less focused on structures and engineering and more on organic shapes. Because of the high cost of sheet copper our costs are higher, and the price must reflect this: $395 per day.
Day 1 - Patterns, Bucks, Mock-ups, and Maquettes
Learn to paper out a shape, transfer solids to flats, and make 3D solids from which to build. What is legal? How creative can we get? This will be "Paper Dolls 101" or "Crafts 206" - taking the idea and working it into a mockup.
Day 2 - Annealing, Shrinking, Stretching, Planishing
This is where the copper is laid out, blanked, and the shape is put into it. We will use hand tools, home made tools, and forming machines to work the sheet into some creative shapes. Annealing, hardening and hot work will be included for your benefit. Embossing and pressing will round out the day.
Day 3 - Tubing: measure, bend, cut, fit, weld/braze
The two types of tubing will be used to show how structures can be made strong with either one. Cutting and bending will surprise you, as I think I can show you unusual methods of bending you may not be aware of, bending tube of any kind. Welding and brazing will be introduced, and then continued on Day 4.
Day 4 - Welding, brazing & soldering, polishing, coloring, and patination
Joining copper (and brass and stainless) to each other can be a wonderful accent to a sculpture, as can patination. Once we learn to weld, braze, and solder this metal then we can think about the final color, and make choices based on weathering, location, or coating the finished piece. Commercial patinations will be used as well as home-brewed concoctions.
Cost: $395 per day (includes breakfast, lunch, materials & supplies).
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