===== Metal Workshop Expansion 2026 =====

Now the woodshop move is complete, we can start work on expanding the metal workshop. We had some useful initial discussion here: https://bristolhackspace.discourse.group/t/metal-workshop-expansion-planning/3925 and the intent is to capture issues and decisions in this wiki

==== Terminology ====

We have decided to split the workshop into 2 parts:

** Machine shop ** (old woodshop): Lathe, Mill, CNC, Pillar Drill etc.

** General workshop ** (existing metalshop): Welding, Grinding, sheet-metal work. Basically anything doesn't involve flamable materials, including oil.

The general workshop area has an enclosed space for welding. The intention is that this will only be for welding.

==== Immediate tasks ====

  * Decide if remaining objects left behind from wood shop move are junk or treasure. Mostly done. Just old workbench and some scrap to dispose of.
  * <del>Paint machine room walls.</del> Done.
  * <del>Paint machine room floor.</del> Done.
  * <del>Move CNC into position.</del> Done
  * <del>Move lathe into position.</del> Done 16-April-2026. Note the lathe now has the new access system.
  * Decide on how to build partition next to lathe.
  * Build partition.
  * Install curtain in new position.
  * Make & install shadow boards
  * Make list of required handtools
  * Investigate if we can use the existing spare extractor for the general/fabrication area. Install if ok.
  * Remove any junk from general/frabrication area.
  * Clean general/fabrication area walls. Remove rawl plugs & fill.
  * Paint general/fabrication area walls
  * Paint general/fabrication area floor
  * Decide on what consumables we should have available
  * Update floor plan, including positions for shadow board, hack rack and parts storage
       
==== Planning ====

=== Constraints ===

  * Fire sensors: The metalshop currently has two, and if we keep the strip curtain, it needs to stay somewhere between these sensors. This does give us a little bit of play for moving the strip curtain up or down the room if desired.
  * Hotworks only insured for welding and grinding.
  * Welding only within an arc-shielded environment.
  * Welding and grinding only within a non-flammable environment. Update: Requirements for grinding need to be clarified. Not as strict as for welding.
  * Welding needs ventilation so either next to the roller shutter or fit the large welding extractor we have in storage.
    * Moving the welding away from the roller shutter would require negotiation with the landlord.
  * Old woodshop has the mezzanine supports which have Intumescent paint. Hotworks might damage the paint?
  * The welder needs a 16A supply which we have by the shutter (plus another in the old woodshop which was installed for the jointer).
  * Wall behind the current wooden metalshop bench has a removable lower panel for access to the laser room.
  * Duncan prefers to keep the door into his half of the building accessible.
  * Lathe positioned with access to feet, 100cm? to the right to allow for maintenance (including removing of thread screw), 50-60cm to the left to allow for access to the gears and for long workpieces, 40-50cm behind to allow access for maintenance. 80cm working area in front. Note: coolant system is below the lathe and its possible future use is still in discussion.
  * We need to ensure there is access to the extractor fan connected to the Laser Cutter.
  * Extractor fans can only vent to the rear of the building. No cutting holes in the front.

[[https://wiki.bristolhackspace.org/resources/install_standard]]

=== Wishlist ===

   * Welding in an area where there is no chance anyone will accidentally enter. The current layout is not ideal.
   * Grinding should be available even when welding is being done
   * Lathe in a position where workpieces that protrude out of the left side will not cause a hazzard
   * Group machines that are commonly used together
   * Separate dirty and/or noisy machines from cleaner/quieter machines
   * Provide smaller 'precision' machines in addition to the larger machines. E.g. benchtop lathe, mill, drill. The intention is that these would appeal to people not confortable with using the larger machines, and would also be more appropriate for smaller workpieces e.g. model-making.
   * Workbenches in the centre of the room (following the woodshop layout). The current plan is for a small but robust workbench in the centre of the machine room. Possibly it will be bolted to the floor.
   * Hackrack (metalshop-specific)
   * Consumables (drill bits, cutters, blades etc.)
   * Nuts & bolts and other common fixings


=== Categories ===


^ Category                        ^ Existing        ^ Planned                    ^                                                                     ^
| Cutting/machining/drilling      | Yes             | Yes                        |                                                                     |
| Welding                         | Yes             | Yes                        | Hotworks                                                            |
| Grinding                        | Yes             | Yes                        | Hotworks and/or old metalshop (TBD)                                 |
| Sand blasting                   | Yes             | Yes                        | Discussed 13-01-2026                                                |
| Paint shop                      | No              | No                         | Discussed 13-01-2026                                                |
| CNC                             | No              | Yes                        |                                                                     |
| Bicycle maintenance             | Yes             | Yes                        | Discussed 13-01-2026                                                |
| Vehicle maintenance             | No              | No                         | Provide tools only. "Metalshop, not a garage"                       |
| Petrol-powered tool maintenance | No?             | Yes                        | Discussed 13-01-2026 Strictly no fuel allowed inside the bulding    |

=== Possible New Equipment ===

All new equipment needs a proposal. Some of the suggestions may not be practicable.

  * Milling machine e.g. [[https://www.chesterhobbystore.com/shop/metalworking-machines/mills/626-turret-mill/| 626 Turret Mill - Metalworking Milling Machine]]
  * Pillar drill + float-lock vise 
  * Sheet metal bender
  * Guillotine (sheet metal cutter)
  * Induction heater and/or Electric kiln. Rejected 13-01-2026 due to safety concerns.
  * Induction forge + tempering setup. Rejected 13-01-2026 due to safety concerns.
  * Plasma cutter e.g. ArcDroid CNC plasma cutter. Discussed 13-01-2026. Need advice.
  * Water cutter. Unlikely to be feasible.
  * Heavy-duty metal fabrication workbench.
  * Standing belt sander to use with metal

=== Decisions ===

  * The metal CNC will be in the metalshop. RHS of old woodshop. Now in (approximate) position.
  * We will move the lathe into the old woodshop. Probably against LHS wall (looking in from the front), just inside the old woodshop.
  * The welding area will stay where it is. (13-01-2026)
  * Plan is to split the workshop into 3 areas: Engineering workshop (old woodshop) for 'clean' operations, welding & grinding area for the most dirty, and the remaining area for those in-between.

=== Questions ===
  - Grinding. There is a wide range of use-cases to consider. Some may have stricter contraints (ventilation, hotworks area) than others (also see 4 below).
    * Categories
    ** Hand tools. Under consideration.
    ** Tool sharpening. TBD
    ** 'Sword-making'. Hotworks area only.
    *(2026-04-09) Current plan is to allow grinding anywhere in the frabrication area, with intensive operations being confined to the welding (aka hotworks) area.
  - Extraction for Lathe and (proposed) Mill. Intensive operations using cutting oil or coolant may create a lot of fumes. Do we need to plan for an extraction system?
    * Assume not for now. We want to keep open the possibility of short production runs which might require the use of a coolant system.
  - 3-phase electrical supply. Second-hand machines using 3-phase are much more common and much cheaper than those that run on single-phase. We have 3-phase to the building and there appears to be nothing stopping us making it available in the metal shop. Machines that might require 3-phase:
    * Lathe (currently has its own 3-phase converter)
    * Mill
    * Pillar Drill
  - General 'hotworks' safety requirements. Would like to get these formalized. Proposal:
      * Level 1: No special requirements. Assumes no fire or fume hazards. 
      * Level 2: Keep away from flamable liquids and materials. Operations that generate occasional sparks. e.g. drilling, hand-filing. 
      * Level 3: Needs extraction. E.g. general grinding, use of coolant on the lathe.
      * Level 4: Needs to be enclosed. Hotworks e.g. intense grinding. Any (fully) enclosed space will need its own fire sensor. 
      * Level 5: Needs to be next to the shutter. Currently only welding is in this cateogry.
  - Curtain. We originally agreed to keep the plastic curtain, possibly moving it towards the front of the building, but do we really need it? We will likely need a separate enclosed area for grinding (where the lathe is now), so it seems there is no need for the curtain. Update (2026-04-09): Think we need a larger fabrication area where we can do all forms of grinding including use of hand-held grinders. So the plan for now is to keep the curtain but move it to just in front of the duct to the laser room.
  - Smaller machines. There appears to be interest in supplementing full-size machines with smaller benchtop machines for model-making etc. A small lathe and mill has been suggested. Do we have support for this approach?

=== Floorplan ===
Several options. So far the only complete proposal is:
[[https://bristolhackspace.discourse.group/t/metal-workshop-expansion-planning/3925/37]]

Other possibilities:
  - Move the welding area to the far end of the old woodshop, making use of the extractor. [[https://bristolhackspace.discourse.group/t/metal-workshop-expansion-planning/3925/53]].
    * Rejected for welding. Still a possibility for some types of grinding.