
December 19, 1932-May 3, 2004
MOST OF LIFE WAS SPENT IN TRYING TO FIGURE OUT A WAY TO DO A $50.00 PROJECT FOR .50¢
By Dave Gingery
When someone asked me for a biographical sketch I was a bit confused and embarrassed so I answered lightly: "Most of my life was spent in trying to figure out how to do a $50.00 project for 50 cents, and the remainder of my time was spent in trying to scrounge up the 50 cents."
No doubt, many of us identify with this statement. Although mildly amusing, it is painfully true. Few of us can produce the ready cash for those projects that may very well mean more to the inner person than does that which we do daily for a living. The result is that we learn to do the impossible by the most improbable and impractical means, but the resulting success is rewarding beyond measure.
That lack of cash that presents itself as an obstacle is really only the medium of exchange for those items of material and equipment we think we need. Actually, a whole list of apparent obstacles holds us back, but the lack of ready cash is the easiest obstacle to recognize and to discuss. As a result there is often too much discussion and too little practical work done. What is really needed is to put the whole matter into perspective so that apparent obstacles can be put aside and we can get on with the business at hand.
You’ll note that I said "we think we need" and "apparent obstacles". It is interesting to note that most of our best ideas meet with opposition in our own minds as quickly as we conceive them. The objections we raise usually seem so reasonable that much of what we might do never gets done. If you don't want to do a project just write down the first dozen or so thoughts that come to your mind and you will have at least a half dozen good excuses. If that doesn't do the trick just toss the idea to the experts and they will usually be happy to kill it for you. If you really want to do it, though, it is most likely that you will find that it does not really cost very much and it is not nearly as technical and dangerous as established experts would have you believe.
Now I don't mean that you should just throw caution to the wind and just light a match or throw a switch and see what happens. There is never a need to proceed foolishly in blind ignorance.
Acquiring knowledge is a relatively straight forward process, and so is the development of manual skill. You can know what others know, and you can do what they do. Your level of performance is determined by a combination of opportunity, energy expended and available resource.
You can provide your own opportunity, and you can decide how diligently you will apply yourself. So, we must deal with the problem of resources which is no small matter if you are the bird with 50 cents who needs $50.00 worth of stuff! Nevertheless, it can be done, so let's get with it while we are yet young and eager.
Reduce the Technology
Since the whole problem is really a matter of determining the difference between what we think we need and what we really need, the first step is to reduce the technology. You will remember from your arithmetic lessons that they tried to teach you to reduce a fraction to its lowest common denominator and to reduce an equation to simple terms. This is much like what must be done to the problem at hand, and it is in itself a delightful exercise. I would urge at this point that you refer to a comprehensive dictionary where you will find that the word "reduce" has at least a dozen distinct definitions and uses. Each of them applies in some way to these matters, so you will be sure to gain from a brief study of them.
Ironically, the reduction of a technology requires a rather full knowledge of it, but you must not let that become an obstacle. Your mind is surely as capable as most, and some have done wonders with even less mental ability. Acquiring the knowledge you need is more of a process of sifting through information than it is learning, so you'll have little trouble unless you try to acquire encyclopedia-like knowledge before you do any work. In this case, it is the excess of useless information that is the real obstacle, so confine your initial study to what is truly basic and fundamental. I'll offer a case in point from my own experience to illustrate the process.
The problem, clearly and simply stated, was to produce metal castings for machinery construction projects in my own shop. A quick look through the library card file turned up a volume entitled "Fundamentals of Metal Casting". Egad! Just what I needed! But, alas, as I took it from the shelf l saw that it was about 650 pages of the finest print I'd ever seen that seemed to have little to say about fundamental principles. Not to be so easily turned aside, I opened it up anyway.
What I needed was there, as it almost always is in any good manual, and most of it was in the first few pages. Of course I needed more information later, but that 650 pages could be reduced to simple terms: a wooden pattern of the desired casting is rammed in moist clay-bonded sand in a two part flask. The flask is opened to withdraw the pattern and then reclosed to pour in the molten metal The result is a duplicate in metal of the wooden pattern.
All else that was written in the book was elaboration of this simple statement. You see how simple it can be when you reduce to the simplest terms possible. This is the result of concentration, and for this you need only your brains, which is the most exotic piece of equipment you will ever own.
By ignoring those excuses that the brain tosses up in order to get out of doing the job, you can quickly sift through the nonsense and focus your thoughts on the first positive idea that comes up.
No matter how high grade your pet idea may be, you should sketch it out in detail, test your reasoning and even make a model of wood or a mock up of poster card. Follow the thought through, and see where it leads. Begin to concentrate on any positive methods that are within your means, and reject all obstacles. You will soon discover a way to use what is at hand or easily obtained to produce some representation of your idea - even if it is only a non-working model in miniature.
This is the beginning upon which you build your entire project. It may take a day, a week, a month or many years, but you will be working at what you want to do without regard for capital, expense, education, equipment or any other fancied obstacle. Later, when you have succeeded, you might look back and wonder at those dangers that might have stopped you, but you were busy at work while others were talking about how tough and costly it would be.
To return to our example, even the most economical equipment to be had at the time would have cost about $500.00. This is a significant obstacle anyone can sink his negative teeth into. At the ratio of 50 cents to $50.00, can you really hope to do the work for just $5.00? Well, I built a foundry in my backyard using scrap wood for the patterns and flasks, a ring of bricks, for a furnace with charcoal for fuel and hair drier for a blower, and a one quart iron sauce pan for a melting pot. This was reduced technology on a reduced budget, and I don't think I blew the whole $5.00. From this simple first step an entire foundry and machine shop have been produced, and it has become a constantly expanding activity.
Important Points to Remember. . . .
Though very convenient, appealing, and doubtlessly worth the price, you can probably produce a practical alternate for most commercial products at a fraction of the going price. Buy exotic equipment if you can, but don't be stopped just because you lack cash to do so.
Practically any machine function can be done manually, though not as quickly as with a machine. Machines are for mass production, but people can produce finished products too.
Knowledge comes from study, and skill is developed by repetition. You can learn what you need to know, and you can practice. Each skill you acquire enhances your overall ability to acquire new skills. (It actually gets easier as you go along!)
The best information is usually found in older manuals because newer texts often assume knowledge of fundamental facts, and they are left out. Even though the new technology was built on the old, it is often beyond the scope of individuals because it requires exotic equipment. Some of it is deliberately disguised, and in most cases worthless for such basic projects as we are concerned with anyway.
You probably already have much of what you need to get started on your project. The rest is merely a matter of concentration and application.
Just in case you think you have it tough, I'd like to point out that it took more work and time to write this column than it did to produce my first casting. Be smart. Let others do the writing while you spend your hours happily busting your knuckles in your shop.









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