Safety in your shop

[Felineman]

I would like to talk to you guys about safety in your shop.

We all use a variety of tools to do the builds and repairs that we do. Below I will list the most common tools that we use and how to use them safely.

*Grinds-NEVER remove the guard or handle, the guard is there incase the blade come off, the handle to properly hold it
*Hammers- Wear safety glasses never use a hammer with a cracked handle
*Drills- Wear safety glasses and never drill towards yourself drill bits like to snap and stab you
*Hacksaw- Always put your work piece in a vise
*When working on exhaust pipe use a chop saw not a grinder grinders can slip out of your hand if they jam and a chop saw also provides a nice even cut
*Always use the proper welding shield when welding, goggles won't do, a shield glass of 7-9 of brazing and 9-11 for mig 11 for arc MIN
*ALWAYS make sure your work area is clean and no fluids are present so that slips, falls and such can be avoided.
*Always mount in a vise all work pieces if it can slip,fall or fly
*All tools should be clean of oil grease or other fluids
*DO NOT MODIFY TOOLS to do a job it wasn't meant to do
*Make sure your bench vise is secure to your bench
*Bench grinders should be bolted to a solid surface
*Drill presses should also be bolts securely to a solid surface
*Eye protection should ALWAYS be worn
*Proper gloves for the job, Don't use flammable gloves for grinding or welding
*Dirt,dust and grime can fall or fly into your eyes at any time so always protect yourself
*Don't leave open flammable fluids around where they can spill, catch fire or cause breathing problems
*Never leave tools on the ground where you can trip over them
*When painting always use a mask and paint in a well ventilated area
*When working on your project if you must lift it up make sure to just jack stands
*Electrical cords should never be left where they can be tripped over
*ALWAYS use a heavy duty cord for your tools, some can draw as much as 15 amp your little cord off the bedside table lamp can melt and cause an electrical fire
*ALWAYS have a first aid kit on your garage
*Always have a fire extinguisher ready on hand in your shop, if its more then 20 feet away its too far
*NEVER change the fuses/breakers for a higher one if your blowing them then your wiring inside the wall is not rated for the tool your using. MAJOR risk of fire
*If you just CUT, WELDED or RAN it, it will be HOT do NOT touch it.

Removing guards can cause accidents like the picture below. I'm fine but got a headache from H3LL right now.

SAFETY IS NOT AN OPTION.

Please sticky will edit as I think of more and better ways to say what I mean If possible save as sticky in the start of every major tread index

 

[xXPhasemanXx]

"When working on exhaust pipe use a chop saw not a grinder."

Somebody want to explain this one to me? Most of these I know why you need to do it but this one is confusing. It's not just enough to say, "Don't do this." You should be telling us what they prevent in doing so. I noticed you did on a few. The main reason why is that if you don't tell us why it's a rule a person may just think it's not that important.

Example: Eye protection should ALWAYS be worn. Not wearing eye protection could result in temporary or permanent loss of vision.

Yes that one is obvious but a lot of new people may not know the safety rules and why they're rules in the first place. I think this could have the potential to be made a sticky if more things are added on.

 

[Felineman]

I'm working on it as you read this will be an extensive list of do's and don't's and the reason behind them

 

[xXPhasemanXx]

I'm working on it as you read this will be an extensive list of do's and don't's and the reason behind them

Alright, can't wait to see how it turns out.

 

[Poboy kartman]

No- sorry..... but I break just about all of those on a regular basis.......

While I don't disagree with most of them. ....some do approach ridiculous. ....as in using a chopsaw to cut an exhaust pipe.......

I think instead of trying to make the world idiot-proof......maybe we should attack the reason that there are so many and work on reducing the number of them!!!!!

 

[xXPhasemanXx]

While I don't disagree with most of them. ....some do approach ridiculous. ....as in using a chopsaw to cut an exhaust pipe.......

Can somebody explain to my why some would say to not use a grinder? I'm just curious.

 

[Felineman]

Using a grinder to cut exhaust pipe leaves you open to the disc jamming and flying apart hense my facial reconstruction today. The disc jammed and flew apart sending the disc and grinder flying. Using a chop saw eliminates the flying grinder and gives you a nice straight cut. Its what they use in exhaust shops. When you use a grinder with a cutting disc they don't withstand much force being only a few millimeters thick.

 

[KartFab]

Wow.... Please, I know that you are shaken up by the accident, but maybe we can focus on what led up to the incident and what should have been done differently.

Tools: were you using the right size disk? Grinding disk or cut off? Cheap? Rated rpm? Too big for the grinder? Guard in place?

Work practices: there is a right direction/wrong direction to cut. Did you have metal bind against the disk at the end of your cut because it was improperly braced? Were you cutting with the edge of the disk or straight through to the center? Was your head off to one side away from the path of sparks/debris? Was the handle on so you could cut straight, one hand on grinder, one on handle? (Or were you holding it like a sword or baseball bat?

Ppe: safety glasses, (face shield or welding helmet w/grind mode), leather gloves or cut resistant gloves? (I wear a respirator when doing a lot of grinding, too but that's just my preference)

I think it is unwise to come up with a gigantic laundry list of always/never statements. These statements need to be seriously critiqued.... In a good way at least..... As of right now I am I'm disbelief that you would even post some of them, out of thin air it seems, rather than on industry best practices accepted by the safety community.

I think it is very unreasonable to sticky this thread.

 

[xXPhasemanXx]

Using a grinder to cut exhaust pipe leaves you open to the disc jamming and flying apart hense my facial reconstruction today. The disc jammed and flew apart sending the disc and grinder flying. Using a chop saw eliminates the flying grinder and gives you a nice straight cut. Its what they use in exhaust shops. When you use a grinder with a cutting disc they don't withstand much force being only a few millimeters thick.

I'm sorry but isn't it like that when cutting everything?

 

[firemanjim]

When cutting tube, I use a chop saw when readily available (don't want to dig it out and set it up sometimes ), but will revert to an air grinder in a heart beat. YES, it is dangerous do to the fact the thin cutting the wheels have a tendency to get hung up and jerks the grinder. I use several styles ALL day long, I'm VERY familiar with them. They work in a pinch, but the SAFEST route IS the chop saw (or band saw due to no sparks or heat)..... I own, at last count, about 17 different air grinders, in different configurations and hp ratings. They are unforgiving to novice users because of the speed they operate at. We use a white soft wheel at work to grind threads smooth. They are rated for 20,000 rpm max. Our grinders are rated at 22-24,000 rpm max @90psi, but we push 175psi through our pipes.... We have had more than several soft wheels blow apart because of operator error (not setting the rpm back on the grinder to start with) .......
IF AT ALL POSSIBLE, wear a FULL face shield when using an air grinder to do any cutting, grinding, or drilling. Remember,@ 20,000 rpm, it don't take long to lose an eye......

 

[landuse]

Here is another thread dealing with safety

 

[Half-breeder]

I would like to talk to you guys about safety in your shop.

We all use a variety of tools to do the builds and repairs that we do. Below I will list the most common tools that we use and how to use them safely.

*Grinds-NEVER remove the guard or handle, the guard is there incase the blade come off, the handle to properly hold it
*Hammers- Wear safety glasses never use a hammer with a cracked handle
*Drills- Wear safety glasses and never drill towards yourself drill bits like to snap and stab you
*Hacksaw- Always put your work piece in a vise
*When working on exhaust pipe use a chop saw not a grinder grinders can slip out of your hand if they jam and a chop saw also provides a nice even cut
*Always use the proper welding shield when welding, goggles won't do, a shield glass of 7-9 of brazing and 9-11 for mig 11 for arc MIN
*ALWAYS make sure your work area is clean and no fluids are present so that slips, falls and such can be avoided.
*Always mount in a vise all work pieces if it can slip,fall or fly
*All tools should be clean of oil grease or other fluids
*DO NOT MODIFY TOOLS to do a job it wasn't meant to do
*Make sure your bench vise is secure to your bench
*Bench grinders should be bolted to a solid surface
*Drill presses should also be bolts securely to a solid surface
*Eye protection should ALWAYS be worn
*Proper gloves for the job, Don't use flammable gloves for grinding or welding
*Dirt,dust and grime can fall or fly into your eyes at any time so always protect yourself
*Don't leave open flammable fluids around where they can spill, catch fire or cause breathing problems
*Never leave tools on the ground where you can trip over them
*When painting always use a mask and paint in a well ventilated area
*When working on your project if you must lift it up make sure to just jack stands
*Electrical cords should never be left where they can be tripped over
*ALWAYS use a heavy duty cord for your tools, some can draw as much as 15 amp your little cord off the bedside table lamp can melt and cause an electrical fire
*ALWAYS have a first aid kit on your garage
*Always have a fire extinguisher ready on hand in your shop, if its more then 20 feet away its too far
*NEVER change the fuses/breakers for a higher one if your blowing them then your wiring inside the wall is not rated for the tool your using. MAJOR risk of fire
*If you just CUT, WELDED or RAN it, it will be HOT do NOT touch it.

Removing guards can cause accidents like the picture below. I'm fine but got a headache from H3LL right now.

SAFETY IS NOT AN OPTION.

Please sticky will edit as I think of more and better ways to say what I mean If possible save as sticky in the start of every major tread index

...Hmmm I honestly dont see any 'reason' to try n list all the safety things, all unorganized, repeated, not fully explained and such. Honestly, noone is gonna search for a listing of "be safe" practices... and even 'if' they did... why would they look in a go kart forum... when OSHA has 'already' made/organized a compounded list of everything you, I, Tom/Dick/Henry, Sally/Suzie/Sandra, could think of... and many 'other' useless 'rules' to follow.

IMO... this post shoulda been in the 'Damage Uncontrolled' post

 

[andrewmacc]

There's absolutely no reason not to use a grinder.

BUT, here are a couple useful guidelines for when you're using them in funky places:

- always cut with the right side of the disc. The clockwise rotation means that if you cut with the left, you increase the likelihood that the disc will bind and explode or catch, injuring yourself.

- always wear good gloves without holes in them, because sometimes just having a good thick glove to deflect the blade will save you from seriously injuring yourself.

- know what you're cutting and how you're cutting it. For example: exhaust pipe will pinch a blade if you have each end sitting on sawhorses, and you cut in the middle. As you penetrate through the exhaust pipe, the weakening structure will begin to collapse inward under its own weight, effectively reducing the diameter of the newly cut pipe, increasing the pressure on the blade. Too much pressure on the blade and it will bind.



These are more realistic statements. To simply say "do not use a grinder for exhaust pipe" is not acceptable.

One other important one a lot of people fail to comply to is don't wear gloves while drilling. Your fingers will not get caught - your glove will, and it will bring your hand with it. If you're using a mill to drill with, you've just broken your fingers, if not more.

 

[Felineman]

First off I was cutting right direct with proper speed setting in a vise and with the guard and handle on. It was only a 12 inch piece, I was cutting a small section to make a new exhaust bend. No I wasn't wearing a shield, my own fault. Yes head was off to the side. Just a freak accident, but could have been serious. And even though most of you know the rules doesn't mean everyone does. My point of this is to educate the younger crowd on shop safety. Common sense is not so common. Many of us remove guards and use tools improperly for many jobs. And Andrew I was a machinist for 12 years, my father for 42 years, trust me we both have had our share of mishaps. Don't even ask how many times we have forgotten the chuck key in the chuck, or the wrench on the bolt on top of the mill. Or slipped in the cutting fluid. Machine shops can be dangerous. But when you add time restraints and working without the proper tools that is when accidents happen. Don't forget the subject of this forum is gokarts and most of the builders here are 12-25, And most of them don't have the years of experience to fall back on knowing what works and what doesn't, so they do what they think will work, either ignoring or not knowing the danger.

 

[landuse]

First off I was cutting right direct with proper speed setting in a vise and with the guard and handle on. It was only a 12 inch piece, I was cutting a small section to make a new exhaust bend. No I wasn't wearing a shield, my own fault. Yes head was off to the side. Just a freak accident, but could have been serious. And even though most of you know the rules doesn't mean everyone does. My point of this is to educate the younger crowd on shop safety. Common sense is not so common. Many of us remove guards and use tools improperly for many jobs. And Andrew I was a machinist for 12 years, my father for 42 years, trust me we both have had our share of mishaps. Don't even ask how many times we have forgotten the chuck key in the chuck, or the wrench on the bolt on top of the mill. Or slipped in the cutting fluid. Machine shops can be dangerous. But when you add time restraints and working without the proper tools that is when accidents happen. Don't forget the subject of this forum is gokarts and most of the builders here are 12-25, And most of them don't have the years of experience to fall back on knowing what works and what doesn't, so they do what they think will work, either ignoring or not knowing the danger.

There are some valid points in there

 

[jandj]

Another tip learned the hard way: Always size up the job first and think about what could go wrong before you start. I spent my entire working life as a mechanic and know that it's not usually the job you've never done before but the job you've done a million times that'll hurt you because you get complacent. Be respectful of the consequences BEFORE you start.

 

[Tomahawk27]

I can attest to keeping the guard on a grinder and using gloves. Was grinding down some welds last night and the only grinder I had available didn't have the guard (was long gone before I started working there). Figured I was okay having eye protection and a fair amount of use with a grinder before but sure enough, my finger caught the edge of the disc and left a good size gash. A trip to the E.R. and a few stitches later, that will be the last time using that grinder

 

[jandj]

Just wondering....why doesn't a prybar have "Do not use as a screwdriver" on it....

 

[88nightrider]

Just wondering....why doesn't a prybar have "Do not use as a screwdriver" on it....

Or why not the other way around also?
We have an old (beefy) flat head screwdriver that as long as I can remember have never been used as a screwdriver. But prybar, oh yes

 

[firemanjim]

All I can say is, safety begins with "you"..... And because we have a mostly young crowd (and old farts like me, lol ) , some of who have never held or used a drill, a welder,even a tape measure. In my honest opinion, there should be a sticky on shop safety,proper use of tools and equipment, personal protective equipment (ppe), and so on..... BUT, I think that it would be too much info to be a truly accurate set of guidelines, that any one would read through it all. How many 13 year old boys are gonna read the boring stuff VERSUS reading the Cool stuff about actually building a kart. I try to throw in some safety tips in a thread when I know that the OP is a youngster and may not know any better. Sometimes, that seems to be the best way to convey a message. The OP is gonna read all the posts, so slip in some safety..... ...... Never even realized what happened, till after he reads it..... And NOW he knows......
On a side note, and I can't believe that I'm gonna admit it, but I seldom wear eye protection when grinding or cutting. But I preach/teach shop safety.... I wear ppe when I feel the risk of injury is far greater than common sense.... I do wear ppe when I know the probability of getting something in my eye is high. Common sense..... For what I do at work, the risk of injury is not high, when proper procedures are followed.... And I tell everyone, DO AS I SAY, NOT AS I DO........you gotta remember that with my 20 years in a machine shop, being a fireman,and having kids, I know a little something about safety. So if I give you some tips a long the way, maybe you should listen. You never know how I learned it, but if I'm passing it on, it must be worth it.......