The guys talk about staying safe in the shop, how to stay safe, wanting to look out for you, and developing good shop habits.  They finish the episode by sharing some of their horror of unfortunate shop accidents; the end gets gruesome, so you’ve been warned!

https://skyscraperguitars.com/

https://www.benhamdesignconcepts.com/custom-furniture-denver-colorado/ 

Brian On Instagram: https://www.instagram.com/benham_design/

Woodworking and metalworking are incredibly rewarding crafts, but they come with real dangers. Even experienced makers can have close calls—sometimes due to complacency, sometimes from unexpected mishaps.

In a recent episode of The Maker’s Quest Podcast, hosts Brian Benham (Benham Design) and Greg Porter (Skyscraper Guitars) shared their most harrowing shop safety stories—near misses, painful lessons, and the hard-earned wisdom that keeps them safe today.

Here’s what we learned.

Greg makes 10,000 identical crosscuts per year on his table saw. Repetition breeds familiarity, and familiarity can lead to carelessness.

“Even with small parts, if they bind against the blade, they can become dangerous projectiles. I remind myself every few minutes to step back, reset, and refocus.”

Key Takeaway:

Pause frequently during repetitive tasks.

Stay aware—don’t let muscle memory override safety.

A dull blade forces you to push harder, increasing the risk of kickback or loss of control.

Brian recalled a debate among woodworkers about blade height safety:

Some argued a lower blade is safer (less exposed).

Brian’s Verdict:

A sharp blade cuts cleanly, reducing the need for excessive force.

Both hosts agreed—router tables are deceptively dangerous.

Catch-and-kickback happens fast.

Vibration can tear workpieces from your grip.

Safety Fixes:

Use fixtures or clamps (not just fingers) to hold small pieces.

Climb-cutting? Only on CNC—never freehand!

Greg’s router fell out of its lift mid-cut, bouncing around the shop like a “weasel-chaser firework.” The long cord kept it powered, forcing him to leap over the spinning death machine to unplug it.

Lesson:

Secure router lifts with lock screws.

Use a dust collection box to contain rogue tools.

Brian adjusted the tool rest of his lathe while it was spinning. The rest swung down, crushing his finger between the banjo and workpiece.

Result:

A blood blister the length of his finger.

Now, he stops the lathe for adjustments.

From Brian’s bridge construction days:

A coworker tried to shear a too-small metal piece on an iron worker.

The metal flipped, smashing his fingers between the guard and blade.

Result: Bones shattered, finger mangled.

Lesson:

Respect the shear guards.

Never force a cut—if it doesn’t fit, find another way.

Greg upgraded to a SawStop—not because he’s reckless, but because losing a finger would devastate his guitar-building career.

His Approach:

Still uses push sticks and guards.

Never test the safety feature—treat it like any other saw.

“I don’t want to be the guy posting a bloody finger on Instagram.”

Brian’s theory: Your dominant hand is always trying to kill your non-dominant hand.

Proof:

At age 10, he sliced his thumb to the bone with a chisel.

Now, he never wears gloves near spinning tools (after seeing a radial arm saw suck a glove—and thumb—into the blade).

Greg’s scariest moment? He got his foot pinned under a car lift.

Couldn’t reach the release button.

Yelled until his wife rescued him.

Lesson:

Steel-toe boots aren’t just for kicking metal.

Always have a backup plan if you’re working alone.

Shop safety isn’t just about rules—it’s about staying present, respecting tools, and learning from others’ mistakes.

Key Reminders: