Click photos to enlarge picture and text.
It all starts with a load of steel from Billings MT.
Once the steel is off the truck we load it into our steel rack.
Steel on the steel rack and ready for the saw.
As with most metal shops, the sawing is the first step to the build.
Cutting the legs to length.
Sawing the frame parts.
Sawing the angles on the frame parts.
All the sawed parts either go to the lathe or the mill next. Here we are turning the ends of the legs after they are welded.
Facing and chamfering the sockets.
Turning the leg cap welds.
All parts in our shop are deburred by hand.
This Cazeneuve lathe is a great machine, they literally do not make them like this anymore.
Our mill, a Bridgeport.
Using a Tapmatic to form threads in the leg caddy pillars, 1/4 - 20 threads at 900 RPM.
Formed threads are used in the caddy pillars.
Milling the 70 degree end on the frame parts.
60 degree saw cuts ready for milling.
A pair of frame parts after milling.
The slot in the sockets is hand beveled to assure years of smooth operation.
A socket after being beveled.
Beveling leg caddy plates.
A good audio book is a real plus, when hand beveling the I.D.s on a batch of leg caddy plates.
Drilling the mounting holes in the frame parts.
There are 700 holes per build, that Grizzly drill press has earned its keep.
Welding is a large part of a build, each bench has 110" of weld.
We strive to keep our welds robust and uniform, to stand up to years of hard use.
A set of nutplates and leg washers. These are the only metal parts not made in our shop, and are made in a CNC shop in the USA.
The Nutplates are made from pre heated treated 4140 and the threads are thread milled for a precision fit.
Weld quality is very important to us.
The grade 8 yellow dichromate bolts are welded into the leg washers with high test wire.
All frame corners are peened and filed for form and function.
It takes twice as long to detail a bench frame as it does to weld it. These are the tools of detail.
Legs welded in the DC positioner.
Our Millermatic 210 welder and Starley DC positioner.
Handle struts, ground and bent, ready to be welded.
Proud to be an American building our products in the USA
Set of 50 benches.
Our KMG belt grinder.
Batch of bench and leg handles after grinding.
Grinding the frame struts.
Set of handles ready to be welded in.
A batch of frame struts ground and ready for welding.
A set of benches loaded up and ready for the 100 mile trip to Billings to be powder coated.
Powder coated frames.
Bench frames back from powder coating.
Building shipping cases, each box has 10 elements to ensure your bench arrives in good condition.
Our assembly line for putting the bench tops on and boxing them up.
Each leg is tried in each socket before it is packaged for shipment.
Every bench is checked by Jeanie, Angus and myself.
How We Build It
ON ALL ORDERS!