First, I was shown the principles of using a MIG welder on 1/4" steel. I had a high quality welder's mask, but I was surprised by how difficult it was to look directly at the metal pool I was using to weld. With practice, however, I could see that the biggest challenges are knowing your metal, following your weld, and mastering the dexterity of the hundreds of tiny circular motions needed for a good, smooth weld. The principles are not difficult, but the production is certainly not easy.
Second, I was shown how to use an acetylene blow torch. Basically, I connected two pieces of metal then blew them apart. Again, keeping consistent motion proved difficult, but the idea of heating the metal to a threshold that would blow 1/4" steel off itself in liquid form is pretty fun. The fundamentals of blowtorching are significantly easier - and much more fun.
After a few days of practice, I am now helping Steve, my friend, produce an oven that will be used in metal molding. His boss has two furnaces that can even melt stainless steel, so our project is to create the molds, build the furnace, and pour knife grade stainless steel into crampon points and other ice climbing gear - making our own Grivel-style piolets seems attractive. In addition, the furnace will take a lot of welding and other metalworking skills, so it will be excellent practice.
We also started making the molds out of ceramic powder and vermiculite (an additive to make the mold easier to break). Word to the wise - if you do this at home, be careful to make the mixture in the correct volumes. Hand mixing is the easiest, especially at this magnitude of production, but the mixture heats as it sets. Warning signs on the ceramic powder attest to this danger. The great danger, however, ended up being timing. To keep the mixture from setting, constanst (hand) mixing is critical. Unfortunately, the mixture will set on your skin, and getting it off is similar to waxing your forearms. It's better to be avoided. Also, as a suggestion to anyone seeking to replicate this procedure, a viscous fluid is the best. Even with the increased water, the colloid will set quickly, and the result is better with a viscous fluid. Also, it's easier to wash off your hands.
Certainly, much more to learn. Look for updates.
