4-Day Metalworking Intensive Workshop

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4 day Metalworking Intensive Workshop TM Tech Kent White

4-Day Metalworking Intensive Workshop

The content covered is tailored to the interest and experience of each group of participants. For this reason, the type of information given, pace, and class projects will vary each time offered. This course has been one of our students’ favorites for several years now.

[Note: This class focuses on using hand tools in conjunction with forming machines for metal shaping—Air Power Hammer, English Wheel, Pullmax, Shrinker-Stretchers. If your interest is primarily on learning to use hand tools for shaping metal, our summer Metalworking Fundamentals course (July 7-10) has more of an emphasis on metal shaping techniques using hand tools.]

Day 1 – Stretching

Class begins with an introduction to the fundamental concepts of metallurgy and the behavior of metals, so that students can become familiar with and anticipate the responses of various metals to specific forces. Students then learn steps for devising solutions to stretching problems they might encounter, including how to avoid excessive thinning while achieving the fastest stretch possible. Forming machines are introduced and contrasted with hand-forming for shaping bowl shapes, hollows, reverses, fairings, saddles, and curved flanges. Annealing, work hardening, and heat-treating are then covered in the context of both making and repairing parts.

Day 2 – Shrinking

We begin by exploring the underlying duality of metal, and how heat and cold, softness and hardness, and thickness and thinness, affect the metal's ability to take on new shapes. Typically we will cover nine or more shrinking methods, with applications for shaping, fitting, and making repairs.

Day 3 – Gas welding non-structural aluminum parts

Using traditional aviation teaching methods, each student is expected to make a good weld in 6 hours, just as aircraft factories trained their welders years ago. We also cover torch and tip selection, regulator pressure settings, fluxes and fillers, and demonstrate joint design, geometry, and distortion. Students are given a basic flange joint to master, and when mastered, they move on to the more difficult butt joint. The day includes 2 hours of instruction, critiques, and demonstrations, plus at least 6 hours of hands-on practice.

Day 4 – Forming Machines

We'll use, troubleshoot, and compare the capabilities of the bead roller, English wheel, Pullmax, and Air Power Hammer.

Cost: $1,595. Price includes all materials, supplies, plus breakfast and lunch.

Pre-req: Metalworking Fundamentals, or several years of metalworking experience, and knowledge of the metal shop environment (common hand tools, measuring, marking, cutting metal, etc.). Class may be repeated, as content does vary from course to course.


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