Building Ductwork With Your Hands

Well, we don't go about building ductwork completely with our hands, but when it comes to fabricating a section of trunk duct for installation, our method is as close to handmade as one might get. Most of the mass produced sections of trunk ductwork and duct fittings are fabricated by machines with giant coils of sheet metal that are mechanically fed. Many of the laborers in these shops are there to monitor and assemble the sections or pieces as they come off the line.

Here at K & E Sheet Metal, building ductwork is a little different. The steps we use to fabricate a section of straight trunk ductwork are old school to most of the fabricators you will come across these days.

So where does the whole process start?

Bingo! You guessed it...

Flat_Galvanized_Sheet_Metal
Flat_Galvanized_Sheet_Metal

We start with a sheet of metal. Our shop is equipped with 26 gauge galvanized sheets of metal that we keep on two separate benches in the shop. For this example we will be using a 48" x 96" sheet of 26 gauge galvanized sheet metal that we have placed on our bench of the same size.

All of our galvanized sheet metal is shipped from the Albany, NY area and needs to be unloaded by hand when it gets to our fabrication shop. We have a table that can be rolled to the front of the shop for unloading, then rolled to each of our tables where it is again, hand distributed to each.

Once the sheets of metal are situated evenly on the tables we can start the process of building ductwork needed for installation.

Hand Tools of The Trade

Sheet_Metal_Hand_Tools
Sheet_Metal_Hand_Tools

No one is ignorant enough to think we can actually cut the sheets of metal with our hands, so obviously some tools are needed to help with this task. For our shop, we use straight cut tin snips for the long cuts, across the metal to cut out flat sheet that will form each L-shape of straight trunk ductwork. If the section was an 20" x 8" x 48" section, we would measure over 20" plus 1/4" for the larger and then from that newly formed line we measure over 9" to  complete the pattern for a half section of straight trunk ductwork.

Why the added 1/4" and 1" you may ask? Well, the 1/4" added to the 20" measurement is for a 1/4" ninety degree bend with our 8' wide manual hand brake and the 1" added to the 8" measurement is for the process of a formed Pittsburgh joint. We will get to both these processes as the post progresses.

We mark the lines necessary in this process with a scribe or awl that etches a fine mark for cutting with the straight tin snips. Once our lines are formed, we make our cut on the second mark that we made because this will eventually be formed into an L-shape of custom straight trunk ductwork. Cutting on the line is crucial and comes with much practice, not to mention building the forearm muscle for making the cuts day after day.

After the main blank of flat sheet metal is cut we can now mark the corners for notching with the proper aviator snips and hand notching tool. The top and bottom of the flat sheet receive a 1" etched scribe all the way across, while the longer, 48" sides get a 1/4" etched scribe on the left side and a 1" etched scribe on the right. After marks are made, each corner and center line--the 20 1/4" mark--are notched for proper loading into the brake and Pittsburgh forming machines.

Rise of The Machines

Our business can be trying enough because we continue to fabricate with an older method. However, the task would be almost impossible if we bent and riveted the straight trunk ductwork with hand tools. Because we are running a business, getting the product to our customers as quick as possible is still a priority, so the rise of some simple machinery is paramount.

Pittsburgh_Cross_Section
Pittsburgh_Cross_Section

Before going any further we should probably chat about the anatomy of a section of trunk ductwork L-shapes. Each L-section has a 1/4" bend and a formed Pittsburgh bend. The 1/4" bend is just a simple 90 degree bend, formed with the brake and it's primary function is to fit inside the marrying Pittsburgh joint.

Pittsburgh_Machine
Pittsburgh_Machine

The Pittsburgh joint is made by hand feeding the flat metal--cut earlier--into what is called a Pittsburgh machine, hence the name. Building ductwork is almost impossible without one of these glorious machines. When the sheet metal is fed through the rollers, the machine creates a pocket with a 1/4" extension that will later be hammered over to form the lock that assembles the finished section of straight trunk ductwork.

Before we do either of the aforementioned bending and feeding, we place the flat sheet metal inside the jaw of our 8' wide manual hand brake to ever so slightly bend a crisscross pattern on the larger, 20" section of the flat sheet metal. After complete, we hand carry over to the Pittsburgh machine and feed the 1" notched, 48" long side through the machine rollers, making sure to keep the flat sheet metal against the fence fixated on the Pittsburgh machine to keep the sheet straight and true.

Brake
Brake

After the Pittsburgh joint is formed we go back over to the hand brake and line up the jaw with our 1/4" scribe'd line that is opposite the Pittsburgh joint. When all is aligned we hand bend and "brake" the sheet metal 90 degrees to form our 1/4" bend. The jaw is opened and we slide the sheet metal out to line up the line we formed in the first measuring process, aligning the jaw of the brake with the line we measured at 20 1/4". The brake is locked down by hand and another 90 degree bend is made to finish one half or L-shape of the complete section of straight trunk duct.

The process is repeated to create another L-shape so that we can finish our section of 20" x 8" x 48" straight trunk ductwork.

Why They Call Us Tin Knockers

The building ductwork process is not complete until we assemble both of our fabricated L-shape sections. The task is simple but time consuming and keeping with the handmade narrative, we use an 8oz. ball pein hammer to get the job done.

Pittsburgh_Hammer_Lock
Pittsburgh_Hammer_Lock

First, we place one L-shaped section of trunk duct on the fabrication bench, Pittsburgh joint up. Next, we flip the other half section, placing the the 1/4" male side into the female Pittsburgh joint pocket. You will be left with a 1/4" sticking straight up in the air. Now we take our hammer and pound over or knock down that 1/4" at a 90 degree angle to finish the Pittsburgh lock joint.

Finish the full section by flipping it over and repeating the latter directions, completing the assembly of a full straight 20" x 8" x 48" trunk ductwork section.

We have been building ductwork for over 20 years and the entire process described takes 10 minutes from beginning to end. Seems short, until an order of 80 to 100 feet of straight trunk ductwork hits the wires.

Clearly we don't actually fabricate the finished product completely with our bare hands. However, in an industry that looks for speed and efficiency like any other, finding a shop that fabricates completely like we do is rare.

Twenty years ago more shops like ours existed, building ductwork the same way we do, but have slowly been going extinct because of lower price and speed. Not being able to keep up with mass production and the lower price points has forced many small job shops out of business. We are still kickin', but there is a daily pressure, questioning what we need to do in order to keep existing business and make it last.

Pretty common in any industry I would imagine.

Learning The FACTS About Manufacturing

Currently I am in the process of researching and acquiring prices regarding larger capacity manufacturing equipment for our micro-business. Although, until this morning, I did not know the FACTS about manufacturing for a business our size or TYPE as stated in a great post on Manufacturing.net by Mike Collins titled "Small Manufacturers Aren't Little Versions Of Major Manufacturers" In the piece he lays out a compelling argument that many manufacturing improvement products are made and marketed to larger companies, but bought and implemented by all. Because of this, these particular programs are abandoned due to lack of results and consultants later ca vetch and make excuses--my conclusion--as to why certain companies couldn't implement the system. However, Mike lays out a better, more logical reason to these issues. Laying out the FACTS about manufacturing systems and process for the range of companies in the industry.

From Manufacturing.net:

I think there may be other explanations as to why many of these process improvement programs fail.

  • Management perceives that the cost of implementation exceeds the expectant results.
  • Tools and program are viewed as too complex and requiring extraordinary amounts of indirect labor hours.
  • The manufacturer is told they must swallow the whole banana bunch (continuous improvement program) to achieve results rather then get incremental results.
  • Smaller manufacturers are told they can use the same program used by Toyota or Caterpillar, no matter what shape their systems or resources are in.

To better understand why many manufacturers back away from these programs you must first understand that manufacturing companies in the U.S. are not a homogeneous group. From more than 30 years of working with manufacturing companies of all sizes, I suggest that there are at least four distinctly different types, and there are logarithmic differences between these types, in terms of resources, knowledge, experience, staff, and the where-with-all to deal with change....Keep Reading

Mike later mentions particular FACTS about manufacturing for companies smaller in size, something I had never heard before and it fits our company to a T.

The second point is that all small and midsize manufacturers are restricted by resource limitations. "FACTS" is an acronym that best characterizes the reality of the small manufacturing environment, described as:

             F - Fear of making a wrong decision

            A - Limited Access to capital.

            C - Cash flow problems

            T - Time constraints

            S - Small or no Staff.

Going forward, as I look into what manufacturing system will fit us best, I will remember the FACTS about manufacturing systems and implementation. The last thing I want to do is make my company machine poor, investing too much in something that will eventually bankrupt us as opposed to helping increase production, customers and cash flow.

Source:

Small Manufacturers Aren't Little Versions Of Major Manufacturers (Manufacturing.net)

Not Letting Anxiety Dictate How to Expand Our Business

Since the beginning of the year I have dredged my brain for answers to the question, how to expand our business. The process has been rocky at times, my therapist helping with the majority of those situations, distraction taking care of the balance. However, I have found that being positive and stopping my obsession with perfect timing has made the job much easier to deal with. Our company is small. If you have read any of this blog in the past, you know this. I have wrestled, through the years, with ideas of how to expand our business, making our minuscule sheet metal fabrication shop bigger. Able to handle larger residential and light commercial projects, but keeping the integrity and intimacy of the shop my father and I currently run. There are plenty of union commercial shops in this area to take the much larger commercial work that I, as a company owner, never wanted in the first place. However, being able to fabricate a larger and quality capacity for our target market is an advantage I would love to have.

When the housing markets shit the bed I learned more in those few years about myself and our business than ever before. Depression from personal and business issues led me and my anxiety to seeking therapy, understanding what I needed in my life to thrive. Since then I have made a concerted effort to be positive, especially in my home life as a whole. Any issues in your personal life will fracture any motivation you may have to make your business a success. I realized this after 34 years on earth and 15 years in business, but it's never too late. There is plenty of time to create a successful business, on the back of what already exists. Something my father and I can be proud of.

The question of how to expand our business looks different to me now than it did a few short years ago. Things are clearer and I know that I must have goals, making strides to build on the foundation my father and I have already built, no matter how small. Keeping our already solid customer base is key, but technology and organization must be something we focus on to satisfy an old and new, growing customer base.

I have been researching and reaching out to find information on the best way we can accomplish our new found goals. Something I never did when I was struggling with ideas on how to expand our business, finding it easier to stay hidden inside an already comfortable cocoon of anxiety and fear. Not anymore.

Don't let the fear of success drain the opportunities that may await.

When I sat in my office, thoughts circling with ideas of how to expand our business, I left every night frustrated and fearful of the next step. K & E Sheet Metal is not a successful business on paper at this point. We are a good business, working hard everyday to produce quality sheet metal fabrication and customers happy with their new furnace or air conditioning installation. We have a lot to learn, which is tough to say for a functioning business of 23 years and counting.

Finding our niche and focusing on goals is what needs to be thought about before leaving the shop each day. Answering that question of how to expand our business and becoming the company we wanted years ago, but never had the courage to pursue is the road we need to follow. There will be tight bumpy corners along the way, but positive thoughts, hard work and focus will make the trip a little easier to navigate.

Is Having No Facebook Page Bad For Business?

Is having no Facebook page bad for your small business?

I hate Facebook with a passion I cannot describe in written language. On the other hand, I love my business and realize that trying to get online eyeballs means finding that place where everyone is hanging out the most. Sadly, that place seems to be Facebook.

We are on Twitter and it is my social network of choice, but most use Facebook for everything. The learning curve is lower than Twitter, so more use the site for their main hub. This annoys me, knowing full well that this is the world we live in and my judgment changes nothing. However, we all bitch and moan about something that we can't change. My crutch is hatred of Facebook.

A little history...

I once had a Facebook page. The one that most people have, jamming with asinine banter about who did what and why they're stupid. The kind where daily baby photos--of the same baby--trump the total number of photos taken of me in a lifetime. Oh yeah, and now everyone's parents can see what you do while out on a date, imbibing till blind and ending up on a strangers couch (not a personal experience). They see and ask about these things like they were in the same group of friends. And then there's the trolling.

I couldn't take it anymore. I needed to get out or suffer the consequences. Having no Facebook page has saved my meager brain from complete annihilation.

But can it help my business?

Running a tiny local sheet metal fabrication shop is hard enough. Finding business the old fashion way can work to gain a few customers, but I want to grow the company into the future. I need to concentrate locally, but where the most eyes are looking and that place isn't the local newspaper or radio.

I never read the local newspaper and pay for satellite radio. If I'm thirty-four years old and look online for everything, it seems logical that as time goes by the younger generation is doing the same and they are the ones who will eventually grow my business. They will be buying homes and installing heat and air conditioning. These are the people whom I need to appeal and make it as easy as possible for them to find me...online.

My point being, if the majority of young people find everything on the web and all have a Facebook page, then having no Facebook page will eventually hurt my company if growth is my ultimate goal.

But I really hate Facebook...

This is true. However, stubbornness will not help a growing and evolving business owner. I have to learn to roll with the punches because honey, I would like to actually own a home (sorry for the lyric change Mr. Zevon)

So do I need to give in and start a Facebook business page? Will it garner me the SEO and traffic to help my business get seen on that great internet ocean we dive into everyday?

I must admit I have wrestled with this for months, it's that hard a decision. I deleted my Facebook page years ago and the nightmares of stressful screen time have finally stopped. Is it worth the impending doom?

Will having no Facebook page hurt any online marketing push for my itty bitty business?

I would love any feedback.

Assembling a Warm Air Plenum Transition

After spending a few days focusing on the company website I figured it was time to get some actual fabrication work completed...so I could finally make a video for our long created, rarely updated YouTube page. Obviously, I am exaggerating a bit, the fabrication never stops around these parts ;) Today I fabricated a warm air plenum transition for a new customer and decided to make a video of me assembling the transition so anyone viewing could get an idea why we are called tin knockers. This is my first "real" attempt at a YouTube video for the company. I uploaded a short one earlier this year, but deleted it due to a horrible camera angle. BTW, my camera, like most, is an iPhone and I make the videos by myself. So please be kind :)

Enjoy and share!!

Leveraging Our Local Business Web Presence to Grow Customers

I may be a little crazy. Well, maybe not crazy, just stupid. I have been working on our local business web presence and company website for some time now and positive as the experience has been, there are days when it seems like an insurmountable task, relegating me to suffer through for the rest of my life. I'm not a cheapskate when it comes to investing in the business, but I do try not to waste where I can. The company website and our local business web presence is one of these not waste kind of investments due to my love of technology and interest in the internet as a business and marketing tool. I'll be honest, I've had my stint in the make money quick affiliate marketing scene once before, which came to an abrupt, money burning ending. However, I did receive an education on some good practices when it comes to building and running a successful website. By no means am I an expert, but a little SEO, HTML and CSS goes a long way when trying to save money with creation and promotion of a website.

Products_Page_Screenshot

Products_Page_Screenshot

Today I began creating the pages for products we fabricate here at K & E Sheet Metal. Nothing too major, mostly pages with our more common sheet metal fabrication to start. Things like:

The hope is that these new pages will give the customer more of a detailed view of what we are capable of fabricating and also giving the engines like Google and Bing the fuel they need to pop us up when a potential customer searches for, as an example "cold air boot".

One thing I am trying to accomplish as a business owner is figuring out how we can leverage the internet and our website to help be a better functioning local business web presence on a budget. Our overhead is costly, so anywhere we can save is a major benefit.

Even though I wear many hats for this company, they are all important and must be cared for individually. Our main products and company revenue are custom sheet metal boxes and fittings, but there are other ways to find streams of income and having a quality website, where customers can find you easily and become more informed on your products is paramount (imho). This is why I am more focused more than ever on creating a higher quality web space.

Obviously, this comes at a time cost, which is valuable, but will ultimately bring solid growth to our local business web presence and customer base. So I trudge through the dashboard of Wordpress and tap away on the keys trying to find the best wording and content for each page, hoping to bring our new and old customers closer to us on the internet.

The challenge continues...

Three Must Have Hand Tools Every Fabrication Job Shop Needs

Must have hand tools are the backbone of our business and the methods by which we fabricate could be seen as archaic to some. Manually cutting, bending and hammering sheet metal to form metal duct and fittings that will reside in a local Glens Falls, NY area home or business. We take pride in the process by which we perform our trade. There are no computerized machines inside our fabrication shop, everything is produced with sheet metal forming hand tools, manually fed brakes, machinery and assembled with the force of human muscle and sweat. Part of this method is based on a dearth of funds for modern machinery and part  the way by which my father and I learned the sheet metal fabrication trade. The intricacy of hand tools, bespoke notches and bends, each one different than the other to form the finished sheet metal duct and fittings.

There are three must have hand tools that I use on a daily basis and ones that should be first in your arsenal as a new or aspiring HVAC sheet metal fabricator.

1. Straight Pattern Tinners Snips

When I was a gangly high school student working in my fathers sheet metal shop in the garage, the first thing I had to learn was how to cut a 48" wide sheet of 26 gauge steel all the way through on as straight a line as possible. The first cut strained my feeble arms, leaving them aching for the entire next day, maybe more. I hated working in the shop when I was young, all of it feeling like punishment instead of making a living for your family, putting food on the table.

Today I realize the importance of a quality tool to perform my job and learned trade, make a living and trying to grow a micro-business in our local community. The straight pattern snips are my most used and important hand tool each and every work day. Honestly, without them I would be out of business. There are multiple pairs on the shop bench, a pair in my tool bag for outside fabrication work and even a pair in my garage for those home projects. As must have hand tools for sheet metal fabrication go, this one is the holy grail.

2. Adjustable Sheet Metal Scribe

There is only one way to attempt cutting a straight line with the aforementioned straight pattern tin snips. Many sheet metal fabricators will use a Sharpie marker to make the necessary marks for cutting and notching. The line is thick and can add or subtract a good eighth of an inch if not cut properly. I learned a different way that has stuck with me to this day. The basic awl and sheet metal scribe create a tight line for me to cut and get the most accurate measurement for bending and hammering each fabricated item. The process may be longer, but the end product is exactly what I expect as a tradesman and what the customer expects from a business.

The scribing process can be tedious, but necessary. From belt scribes to hand scribes, there are many different types you can use to get the necessary line for cutting and bending. I keep one on my belt (Belt Sheet Metal Scribe [Misc.]) and one on the bench for scribing marks when bending flanges, 1/4" marks for the male pittsburgh bend and much much more. The scribe is as important as the artists drafting pencil, easily making the must have hand tools list.

3. 3-Inch Offset Handle - HVAC Hand Seamer

Not the most popular, but when our brake can't get the job done, the hand seamers can be our best friend for those pesky inside throat bends. When I fabricate a custom sheet metal 90 degree elbow, the inside throats are always bent up with angle hand seamers.

For the entire 13 years I have worked for K & E we have not owned a box and pan brake for making many of those inside and flanged bends. Getting creative has been the only way to make the bending process easier and hand seamers are the number one must have hand tool to help that creative bending process. Whether in the sheet metal shop or on the job site, sheet metal bending hand seamers are a must have tool for any working or aspiring sheet metal fabricator.

Mine have been an extension of my arm for a long time, sometimes straight for those intense bends and angled for the harder to reach places on top of the duct line or bending out flanges on the sheet metal plenums. A must have.

A new tradesman never knows where to start when assembling a tool set for performing their craft. For the new sheet metal fabricator I would suggest these three must have hand tools to start any set of fabrication tools. There are many more that will be necessary to make the most of your sheet metal job shop, but this is a great place to begin the journey.

Want some more hand tool ideas or just want to replace some of those old sheet metal hand tools? Check out our online sheet metal tool shop.