Zap and Dylan catch up after a busy stretch. Boise expansion, Texas customer visits, QuickBooks meltdown, and the Claude Code build. Dylan's still chasing power for the Flex, doubled up compressors, and is increasingly frustrated with Fusion. Plus questions on specialization, work holding, financing, and the worst shops Zap's walked into.

Check out Zap's IG @zap.consulting

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Brian Kippen is back after nearly four years to talk about an incredible period of growth and change at KAD Models. From teaching machining to acquiring a wire forming business, adding a MAM with automation, and managing three facilities across two coasts—all while raising a toddler. We dive into the cultural challenges of bringing precision work to a fast-paced prototype shop, the reality of machine automation ROI, and why delegation is harder than it sounds.

Check out Brian's IG @kadmodels

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Zap and I wrap up 2025 with our first live podcast! Patreon members join us as we answer questions, reflect on 2025, and talk about plans for 2026. Thanks to everyone for a wonderful 2025 and looking forward to a great 2026 with more guests and episodes!

McMaster Ugly Sweater - https://laurenfahey.me/mmc-ugly-christmas-sweater/

Keyence Sensors are - FR-S01 for radar level sensing and FI-C20D for refractometer

Check out Zap's IG @zap.consulting

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This week I talk with Ethan Perrin about MIT Formula SAE, building the Miters West shop, and why a small fiber laser and press brake changed how he prototypes. We also hit rescuing CMM's on a budget and his alumni EV formula car.

Check out Ethan’s IG @ethan.perrin97

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In‑person catch‑up: pre‑Flex rigging shuffle, neighbors bribed with donuts, and the first HyperMill customer part. Zap runs through leaving Boise, growing the team, splitting work the right way, and getting a shop moving with CMM, coolant, and probing.

Check out Zap's IG @zap.consulting

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We catch up on a busy stretch: Zap’s UK stint, dialing in systems, and turning chaos into consistency—including saying no when it counts. Dylan locks the shop layout, keeps the S700, preps for the Hermle HSFlex and hyperMill, and shares a few hard-won long-cycle lessons.

Justin's Speedio Filter - https://marketplace.sendcutsend.com/p/CD80E306/chip-filtering-grate-filter-for-brother-speedio-s500-and-s700 Check out Zap's IG @zap.consulting

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From an 800 sq ft pole barn to a 4,000 sq ft shop, Devin shares how Lichen leveled up: team, layout, and automation. We cover the R450 cobot project, M300 wins, live‑tool lathe realities, and building a stable, sustainable operation without the chaos.

Check out Devin’s IG @lichen_mfg

and check out his podcast Incremental at https://open.spotify.com/show/5pjzm7sFZrumDHv2eqytg5

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Curt of Confounded Machine shares how a garage hobby became a thriving EDC pen brand. We dive into retrofitting a Hardinge, moving to a Syil X5 , iso-grid grips, entropic anodizing, and his new “Mech One” mechanism.

Rigibore RADS video mentioned: https://www.youtube.com/watch?v=o0pM5cKUKSA

Check out Curt’s IG @confoundedmachine

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Jamie Peacock of JSpec Engineering and The Lone Machinists podcast joins to talk one‑man‑shop reality, from building and retrofitting machines to launching the Anchor Point zero‑point system. We hit in‑house anodizing, adding a 4th on Siemens, and why relationships beat everything in business.

Link to the article discussed in the episode: https://www.linkedin.com/pulse/lets-talk-cheap-labour-expensive-mistakes-danica-peacock-cqrsf/ Check out Jamie's IG @jspec_engineering

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California updates with Zap, CMM finally dialed in, HyperMill setup progress, pin finisher optimization, RO water planning, and some honest programming errors. Topics include surface roughness tools, machine comparisons, cost tracking, floating tap holders, and technology perspectives.

Check out Zap's IG @zap.consulting

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Help support the podcast www.patreon.com/withintolerancepodcast