Strategy & Tactics

TEN Practices for Safety and Security

Review essential safety techniques and improve efficiency at your shop with these recommendations from top industry professionals.

WORDS BY ROSA SOPHIA

Certain best practices in the shop are worth reviewing, especially safety techniques. At KnowledgeFest.Live in December, Jason Kranitz of Kingpin University, together with Chris McNulty, gave a presentation on the theory and demonstration of shop safety techniques. They discussed routers and table saws, as well as the utilization of jigs, shields and other safety devices. Kranitz stressed how important it is to avoid becoming complacent in the shop. He emphasized safety issues “especially when working long hours. You’re tired, and you don’t realize you’re doing something wrong.”

While focusing on safety in the woodshop, Kranitz talked about templates and jigs, which can be made of various materials.

In this month’s installment of Strategy & Tactics, we take a closer look at some of the safety techniques discussed, as well as some other tips offered in the Industry Best Practices workshop presented by Brandon Green of The Car Audio Shop and Josh White of Auto FX.

#1: Never Take Shortcuts

Kranitz told viewers there’s no such thing as shortcuts. “If you try to take a shortcut, or do something without the proper technique,” he said, “you’re only creating what I call ‘long-cuts.’” Shortcuts often make for added work and mistakes that must be corrected, which means the task will take twice as long as it would’ve had the technician started out using the correct method.

#2: Always Precut Before Using the Router

Precutting your product is important, according to Kranitz. “If you have a circle, for example, and you aren’t cutting that in or out—once that catches on the bearing, it can bounce around, smash your finger, damage the product or even hit you in the eye.” To underscore his point, he stressed again and again that it’s possible to lose fingers if safety isn’t kept top-of-mind.

“If you don’t precut,” he said, “your part could be destroyed, and then you’ll

have to go back, start over, and precut anyway. Take every safety precaution possible.” Don’t take chances, he advised, adding, “In these situations, you might feel like you got lucky, but the next time could be the time you get hurt.”

#3: Wipe Templates After Use

Dust collection on templates will affect efficiency and safety, Kranitz said. All templates should be properly

cleaned—not just wiped on a handy t-shirt. “Your template can be plastic, PVC, acrylic or wood, but you still have to wipe the template, or the fine dust will be there,” he explained. “You want to make sure you completely clean it so you have a good mechanical bond. Otherwise, when you go to router, it’ll slide off and you’ll have to start over.” He noted this is also a safety issue: “If it slides, you could get your fingers caught on the router bit.”

#4: Always Double-Back Template Tape

When using template tape, Kranitz advised, “Make sure you double-back it. If I have a long rectangle and lay down template tape, and it’s already rough-cut, the template can still move,” he explained. “Double-backing it will stop any kind of movement. Always double-stick any time you’re using templates.”

#5: Essential Proper Use of a Router Bit

Since a router is used in fabrication on a daily basis, Kranitz said it’s important to stay focused and maintain proper use. He said he begins cutting at the six o’clock position, then goes counter-clockwise to completely router the rest of the part. “Make sure to use the proper router base, too,” he added, noting the importance of taking every precaution to stop the material from dragging or pulling.

#6: The Proper Use of a Table Saw

Kranitz recounted work-related accidents he witnessed at previous places of employment, and said, “When someone cuts themselves on a table saw, it’s usually because they’re doing something they shouldn’t be doing, or they’ve become complacent. I’ve heard many times, ‘I don’t need a guard—I’ve been doing this for years.’ When you’re cutting anything under an inch, you have to remove the guard. We get that. However, it’s rare that you have to cut something at less than an inch.”

If this is the case, Kranitz advised considering another method. “In that case, is there a better tool available? If the table saw is the only option, the guard comes off,” he added. “But we don’t want to use our fingers or we’re asking for problems.”

The answer to this, he said, is to use a push stick. “And if you aren’t comfortable with it, learn to get better using it.”

#7: Essential Table Saw Safety Tips

Always keep a sharp blade on the table saw. Additionally, make sure the blade is appropriate to the material being cut. According to Kranitz, these essential points in table saw safety should always be followed: •Do not try to stop the blade while it’s moving, no matter how slow it’s moving.

If you use a blade shield, this prevents that.

•Do not wear loose clothing. This can pull you in if it gets caught.

•Do not cut on the table saw while wearing gloves. This adds baggy material.

•Do not put liquid containers or drink containers on the metal surface. It will leave rust rings. This surface should be as smooth as possible.

•If the surface is dirty, use your sander on it, lightly with 400 grit sandpaper.

•Wax the top of the table saw. It will ensure materials slide through easier, and it won’t bind, making for a safer cut.

#8: Always Wear Safety Glasses and Proper Ear Protection

During his presentation, Kranitz stressed the importance of wearing safety glasses and proper ear protection. “I’m very particular about my ears, and so I got them tested. I have good hearing, but I don’t want to be doing this as a career and one day find I’m unable to enjoy it,” he said, adding that headphones don’t count as hearing protection. If an OSHA

representative sees technicians wearing headphones instead of proper hearing protection, Kranitz noted they will fine the shop.

“While those of you who use headphones might want to argue this point, this is a safety issue,” he said. “When I’m running a router and I hear a different speed I’m not used to, I will notice the bit is loose or the bearing is loose. If you can’t hear that because you’re listening to music on your headphones, there’s an issue.”

Furthermore, he added, if something happens and a coworker attempts to warn you, but you can’t hear them, this can make for a dangerous situation. “I also like to wear an apron because it keeps my work clothes cleaner, and it’s more efficient because I can put my tools in it,” he said.

#9: Create a Separate Design Area

Some might be tempted to do all the work in the same area, Kranitz said. “There’s nothing worse than having to move all that, scooting it out of the way.

It’s dangerous if it’s on the same table as the saw. Put everything in its place.”

The shop should have a designated area for a design table complete with pencils, pens and measuring tools, as well as anything else necessary for assembling, building or layout—including template tape, he added.

#10: Safety and Productivity Go Hand-in-Hand

Also during KnowledgeFest.Live, the popular Industry Best Practices for Technicians and Fabricators workshop was presented by Brandon Green of The Car Audio Shop in High Ridge, Mo., Josh White of Auto FX in Tacoma, Wash. and Adam Devine of Devine Concepts in Naples, Fla. The presenters touched on some of the same points discussed in Kranitz’s class, emphasizing the fact that safety and productivity go hand-in-hand. They also discussed fabrication basics and wiring of electrical components.

When it comes to the router, Green said, “Be productive and efficient. Use industry standards. Learn from others in the industry by networking online, and attend fabrication trainings.” Following up on some of the discussion in Kranitz’s safety class, Green added, “You want to make sure the piece you’re working on is fully secure. It should be adhered well and solid.”

The other presenters echoed this advice, while White added, “Get organized. And make sure to keep whatever you use frequently in-stock.”

TECH TIPS: Threaded Inserts and Magnets

Brandon Green of the Car Audio Shop demonstrated examples of threaded inserts in use in a Bentley during the Industry Best Practices workshop session at KnowledgeFest.Live. He showed two enclosures. “We used two different types of threaded inserts to mount these together and to mount the subwoofers into the box itself so everything was completely serviceable.”

“Here are examples of a metal amp rack we did in a 4Runner,” Green said. The rack is shown above. “This uses

different materials, composites and metal, using threaded inserts to mount it. This is similar to the Bentley,” he added, noting that the build was designed in such a way that it’s easy to remove and re-install. Green added that The Car Audio Shop had to do additions to the build, and each time they removed it, it was easily put back together. “This also shows examples of wire-running,” he said.

Josh White of Auto FX stated that he keeps magnets in stock. “We recommend keeping at least two different sizes on hand,” he said. “You can stack these two-high, as well, if you need more pull. They are really good for non-structural trim pieces that you might want to hide so no fasteners show. There are a couple of tricks out there.” He noted Car Audio Fabrication as a good resource for tips on using magnets in a build. Green added, “Be sure to sand them down before you glue them, too, or the glue won’t hold indefinitely.”