cutting

Building things from metal can seem intimidating—metal just feels so much more permanent than, say, wood, and with the all the sparks and pressurized cylinders, it seems like just a matter of time before you blow up your shop. But once you know your way around a few key tools, you'll be amazed at how simple metalwork can be. Case in point: the plasma cutter. This small, relatively inexpensive machine has one dial, no cumbersome gas tanks, and can zip through any conductive material faster than a jigsaw through pine. It's also basically a sci-fi machine made real (c'mon, it slices through steel with hafnium and air!). And since they're for sale in most big-box home stores, you can even put one on your X-mas list. Master this, and your metal creations can take on just about any shape you want.

MIG welders and plasma cutters might carry more cache, but serious metal cred comes from the mastery of a simple flame. The oxy-acetylene torch setup is one of the most affordable versatile tools in any shop. With it, a competent operator can heat, weld, braze, silver-solder, and cut. We've used it for all of the above, but it's most often used to heat steel for bending and to cut. Cutting with the torch is so incredibly simple and cost-effective compared to plasma cutting— especially for thicker materials—that it cannot be ignored. Fortunately, it's also not that hard to learn. Here's a quick primer to the tool every metal shop should have.

Whenever you run into a snag on a project, it's a pretty safe bet that somewhere there is a grizzled old man who's solved it many years before you and will be happy to tell you it. That's why I never miss the chance to chat up the old guys working at or just hanging around lumber yards, machine shops and scrapyards. I always walk away smarter.

One recent example: While helping PopSci's John Carnett with his Green Dream house, we had to make a number of bolt holes in thick structural steel. (I would have preferred that the beams had come from the steel yard properly cut and drilled, but sometimes things don't work out as we'd like.) The drill just wasn't cutting it, so I turned to the oxy-acetylene cutting torch. It would easily pierce the thick steel, but I wasn't sure it'd cut clean holes. Then I remembered a great trick for burning accurate holes that I learned from an old-timer at the structural steel yard.

I love rebar. It's most often used in concrete as a reinforcement, but it has a ton of uses. I've made a fence, a shed, and my future dome home armatures all from rebar. And since it's often made locally from old cars, it's relatively planet-friendly, too, and not very expensive. A 20-foot-long, 3/8-inch thick stick normally costs me about $4. I've purchased more than three tons of the stuff from a metal plant near the El Paso border, about 100 miles from my home.