Understanding Our Custom Sheet Metal Business

The custom sheet metal business has many facets and can be thought of as many different things. Because of this, we receive emails and calls for many different types of fabrication that we, as a sheet metal shop, may or may not be able to accommodate. However, this does not mean every job is something that is right for our fabrication shop or business in general.

With that in mind, I did something earlier this week that I hate doing. Especially in the business environment that we and many others find ourselves confronting daily.

For the first time in a long while I gave up a project that I would have given my left arm for just two years ago. However, the project had one major flaw that, up until now, I had never payed attention to and it drove me to stressful, anxiety filled places where I never want to be again. The kind of place that made me question whether or not trying to keep the doors open was even worth it in the end. The kind of job that, honestly, was too big for our tiny custom sheet metal shop to handle. A job that would have payed well, but stretched our time frames and kept the stress throttle to the maximum it could handle. Like I said, a place I never want to go back and visit.

K & E Sheet Metal is a niche custom sheet metal business that focuses on the residential HVAC markets. We are a job shop that caters to customers that need something in a pinch or small HVAC contractors requiring custom transitions or plenums when replacing a customers dwindling or broken forced air furnace.

My father and I knows this.

The problems arise when the big projects come down the pike, the rose colored glasses move down off the brow and dollar signs fall from the skies like showers in April. The lead times seem perfect and the voice on the other end of the telephone, in reassuring tones, makes everything seem like nothing will be a problem. We have plenty of time. Nevertheless,time passes quickly and small items are slowly finished. We are a one man operation pretending to be the robotic armed assembly line of the Ford Motor Company.

I take care of a few old, returning customers and before you know it the phone is ringing, the time window is closing fast, I'm working late now and on the weekend. The stress builds and nothing seems to satisfy the beast of time because there's none of it, never enough time in the day to accomplish what you need to. Why did I take this job? This is too big for our shop. I can't do this all by myself and we don't have the resources to hire any help! Get me the fuck outta here!!

In my drinking days, these kind of scenarios ended at the local pub. However, I am older now and understand this is not the way to run a business. Something needed to change and it started with me understanding what we were all about.

There is a market for the kind of custom sheet metal work we provide. K & E has been providing this service in the Greater Glens Falls area for over twenty years and we continue today. The things that I, as partner and chief fabricator, never focused on was understanding what we do. I didn't pinpoint my efforts toward the strengths we possess. K & E Sheet Metal provides a necessary service for the little guy and we--and I-- need to be proud of that fact. Not shy away from it, but embrace it. The stress of trying to be something we are not made me lose interest in the business as a whole, leaving gaps where we may have been able to grow. Instead I tried to find easy ways out, looking for ways to expand where we didn't have expertise or the money to make the proper impact. Sometimes breaking it down and starting from scratch is the best way to find your identity as a business and as human beings. Getting rid of the clutter and focusing on yourself, what you do and how you can focus your skills to help others is the best avenue. Personally and in business.

My father and I have learned the hard way that trying to be something you're not isn't the best way to find business success. Bringing a positive attitude, focusing on your strengths and producing quality custom sheet metal fabrication is what will ultimately make us successful. We may not be millionaires, but we will run a quality, well functioning business in our local community of Glens Falls, NY.

Completed Custom Y Duct Fitting From Earlier Template, Sheet Metal Fabrication

Earlier today I tweeted a photo of the template for a Y duct fitting that I was starting to fabricate this morning.

These fittings don't come around all that often, so many times I will have to relearn the process when asked. The process is not overly difficult, but because much of our work is done by hand and there are no computers to hold a file I can just punch up, it can take some time. Many of the custom duct fittings I make are specific to measurements for any one job, so many things are fabricated only once and the process forgotten.

Our stock items are easy to fabricate from templates and make the same way every time. The custom fittings are much different and really the reason we are here in the first place. We fabricate fittings that can't be found in stores, so there is a level of customization and care that goes into every piece.

Below are a couple photos of the finished Y duct fitting I fabricated this morning.

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The Lenny Harris of Sheet Metal Fabricators

I am the Lenny Harris of sheet metal fabricators. Lenny Harris was one of the best, if not thee best, pinch hitters in baseball during his career. He had the most pinch hit at-bats (804) and the most hits (212) in pinch hitting situations.

Since the beginning of the year and over the course of the last few years I have filled in as a fabricator for a larger, past customer. They decided years ago that housing their own fabrication shop was best for them and no longer needed my services. However, I kept up good relations and when their main fabricator has been ill or out of work, I have been on the list to come off the bench and pinch hit.

The money we generate from this company is and was much larger than most customers I fabricate for, creating a nice stimulus. For this reason, burning the bridge and creating a rival competitor was something I was not willing to do. With any micro business, if you provide a service and do your best job possible, someone will always need what you are selling. Without the trickle down business these companies provide, micro businesses like ours would have trouble surviving.

I could have been very caddy and hurt that a solid customer of ours was moving on, leaving us to find other revenue sources. However, business is business and I don't control what others do with theirs. I knew that we might be needed again in the future and I didn't see the point of making them out to be a villain, trying to hurt the little guy. Sometimes it pays to be patient and realize that things come and go in any business. Only diamonds are forever.

Sadly, yesterday was the last day of my pinch hitting duties, but I will be swinging a bat in the tunnel getting ready for my next assignment. Always be prepared, you never know when your number may be called.

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Custom TEE Template to Start The Fabrication Process #sheetmetal #fabrication

20120210-100212.jpg My template for eight custom TEE fittings is complete and redesigned. I used to make the V at the top a little more abrupt than on this particular template. With this one I widened the V, which makes it easier to assemble than before.

Now I must trace and cut out 16 of these by hand, along with the other pieces that will eventually finish each TEE. After they are cut out and bent accordingly I will have to line them with 1/2" acoustical insulation.

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Knocking Out Trunk Duct Reducers in Bulk Lately

My father and I have been busy fabricating trunk reducing transitions for multiple customers of late. They have really caught on as an easier way to reduce the trunk duct line. Many of the builders we fabricate for have been using a prefabricated side piece that you have to cut-in on site when reducing the trunk line. The process is time consuming and cumbersome. Our reducers are a cost effective and efficient way to install the duct.

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Fabrication Process of a 22 Gauge Support Box in Tweets

Yesterday I was tasked with fabricating a 22 gauge support box with accommodation for a filter rack and cold air drop for a furnace. The box needed to be 16" tall, 20" wide and 48" in depth, equipped with a 16" x 20" filter rack and take-off for the 12" x 20" cold air down drop. The total fabrication took most of the morning, roughly three hours and I decided to tweet out some of the process. Below is the timeline of tweets.