Metal Fabrication

Made a press brake to assist with other shop projects

Built a welding positioner supporting several hundred pounds with infinitely variable rotation speed and 90+ degree tilt using sheet metal and timing belts

Large mitering bandsaw for rapid stock removal

3/4 HP horizontal/vertical bandsaw with 4-1/2" x 6" cutting capacity

CNC plasma cutting system with cantilevered gantry for precision sheet metal work

Some of the most productive tools in the shop are those that are fastest to use

Despite its obsolescence, nothing can compare to the flexibility and sheer number of axes of a tool-cutter-grinder

Fabricated custom front and rear steel bumpers with integrated shackle mounts and receiver hitch for a Bronco

Designed and welded a custom sub-frame to mount a crane on a work truck for stone sculpting operations

Designed and fabricated a custom bow system with integrated trigger mechanism and adjustable elevation hinge

Mounted a cast-iron fixture table to my adjustable-height Portelevator cart

Created a sculpture as a gift for a friend

Discovered that applying power to the motor restarts the engine, enabling microcontroller-based engine control

After buying my friends each a mini-bike kit this was our first attempt

Documented end-to-end fabrication workflow from material marking through final assembly

Repaired structural components on a vintage Harrison L6 Mk1 lathe using aluminum welding techniques

Designed and fabricated a sculpture of the logo of the company I worked for

Converted a bicycle to a penny-farthing configuration, achieving geometry precise enough for hands-free riding

Engineered layered petal assemblies by designing and folding individual petal sections into a cohesive structure

Designed and hand-fabricated a complete custom motorcycle frame from scratch, progressing from initial drawings to a ridable prototype

Built a welding cart as a first project to practice and refine basic welding techniques

Designed and fabricated a weld cart

Many hours of experience with welding steel

Built a digital fabrication pipeline converting mountain terrain data into 3D-printed candle molds, automating geometry tuning too complex for manual adjustment

Developed terrain-derived candle products using digital topography, custom molds, and iterative fabrication

Migrated a CAD toolchain from Jupyter to marimo by forking and refactoring cad-viewer-widget, creating marimo-cadquery, and building purpose-built map and mesh viewer widgets

Tracked physical artifact provenance by linking mold lineage to wax-cam commit hashes, enabling reproducible terrain-derived candle designs

Built a reproducible terrain-to-geometry pipeline using Jupyter notebooks, TouchTerrain, and CADQuery to iterate on 3D mountain models for fabrication

Built a CAD/CAM workflow to transform real terrain data into iteration-ready geometry for wax sculptures

Reverse-engineered a legacy Staübli RX90 robot controller and replaced its failing floppy boot disk with a ZuluSCSI SD card emulator after six disassembly iterations to derive a working boot image

Acquired and transported a 330KG industrial robot for $1,800 using improvised strapping and winch rigging

Revived decades-old industrial robot hardware by emulating legacy SCSI storage with a modern SD card