Within Tolerance

Within Tolerance is a podcast where the hosts talk everything from machine shop work, CAD/CAM, and other manufacturing processes!

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21 episodes
Avg 1 hr 53 min
English

Episodes 21

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Friday · 2 hr 10 min
Within Tolerance Episode 282 - The Bot Will Remember This with Zap
Zap and I go live one more time before IMTS with Patreon members firing off questions. We map out the meetups (Kern on Wednesday the 3rd, plus a rotation of podcast recordings around the show floor) and swap updates: Zap on Kinematic Sauce, CritLink, and nonstop coast-to-coast travel, me on the new auto CMM, the coolant dosing project, and the podcast bot that's now live in the Discord. Plus a Fraisa vs. the world taper battle in 17-4.Check out Zap's IG @zap.consulting-----------------------------------------Help support the podcast www.patreon.com/withintolerancepodcast
August 11 · 43 min
Down the Rabbit Hole with Justin Gray EP4 - Standard Tools Are the Cheapest Automation You Can Buy
Justin and Zap are back for chapter four of My Tool Library Is Better Than Yours: Standard Tools Are the Cheapest Automation You Can Buy. Standardizing saves you a little time every day, but the real money is in killing the expensive outliers that blow up a Saturday night. They get into what "standard" actually means (it's not one holder for everything), why drills and taps are the best place to start, buying a holder or at least a collet with every tool, and keeping a bullpen of ER holders for the one-off cutters. Plus the pull-stud fix Justin talks himself into live on the mic.Justin's IG @justingraylabsZap's IG @zap.consulting-----------------------------------------Help support the podcast at www.patreon.com/withintolerancepodcast
August 4 · 2 hr 38 min
Within Tolerance Episode 281 - Eddie Riddell of Steele & Co Engineering
Eddie Riddell of Steele & Co Engineering joins Dylan this week from his one-man job shop in one of the most remote cities in the world. Eddie traces a wild path from a New Zealand apprenticeship to the Australian mines to going out on his own, buying Haas machines sight unseen from across the world and landing on a DN Solutions SMX mill turn. They get into learning G-code out of necessity, why turning tools in Fusion are a nightmare, and the fixtures that have no business working but do. Plus the payment dispute he settled with an angle grinder.Eddie's YouTube for his boat, container house, and other builds: https://www.youtube.com/@eddiereddierEddie's IG @steele_co_engineering-----------------------------------------Help support the podcast www.patreon.com/withintolerancepodcast
July 24 · 2 hr 22 min
Within Tolerance Episode 280 - Long Lists and Kinematic Sauce
A long overdue catch-up with Dylan and Zap. Dylan owns up to overcommitting the shop and relearning that automation doesn't save you from yourself, then runs through tooling, RO water, and a 3D printer that ate itself mid-print. Zap talks Kinematic Sauce, building systems that persist without him, and why being cheap is the fastest way to sink a shop. Plus neat oil, buying machines the right way, and a vice that took a swan dive into the chip bin.Check out Zap's IG @zap.consulting-----------------------------------------Help support the podcast www.patreon.com/withintolerancepodcast
July 23 · 25 min
Down the Rabbit Hole with Justin Gray EP3 - Always Be Auditing
Justin and Zap dig into the idea that a good tool library is never finished. They cover treating it as a digital twin of your crib, promoting tools from bench to standard, and when it's fine to let a specialty tool live outside the system entirely. The theme running underneath it all: seek perfection if you want, just don't let it stop you from starting.Check out Zap's IG @zap.consulting-----------------------------------------Help support the podcast www.patreon.com/withintolerancepodcast
July 7 · 17 min
Down the Rabbit Hole with Justin Gray EP2 - My Presets are Better Than Yours
Episode two digs into presets to boost throughput in CAM. Justin and Zap break down the golden rule—if you're dialing in feeds and speeds every single program, you need a preset—plus how far the rabbit hole goes with floor finishing, wall finishing, tape-and-glue, and everything in between. Plus why the same carbide in a different holder isn't the same tool at all.Check out Zap's IG @zap.consulting-----------------------------------------Help support the podcast www.patreon.com/withintolerancepodcast
June 27 · 28 min
Down the Rabbit Hole with Justin Gray EP1 - My Tool Model is Better Than Yours
Kicking off Down the Rabbit Hole, a new Within Tolerance podcast for nerds, by nerds. Justin and Zap launch their multi-part series "My Tool Library Is Better Than Yours" with the bootstrap basics: a simple four-folder structure, modeling your holders and tools accurately, and getting roughing and finishing presets dialed in. No money required—just stop building tools from scratch every damn time. Links mentioned: Fusion Essentials - https://github.com/Kings-Mountain-Labs/Fusion-Essentials Check out Zap's IG @zap.consulting ----------------------------------------- Help support the podcast www.patreon.com/withintolerancepodcast
June 12 · 1 hr 6 min
Within Tolerance Episode 279 - Down the Rabbit Hole with Justin Gray
Justin Gray catches us up on life post-Toolpath. We get into Justin Gray Labs and his vibe coding kits — along with the security nightmares they're built to prevent. He's also chasing fidget pistons to a two-tenth window on a Syil and Speedio. Then we get into Kinematic Sauce, the calibration algorithm he and Zap built for Speedios, with Fanuc and Haas next. Plus, his new show Down the Rabbit Hole is launching soon here on Within Tolerance! Check out Justin's IG @justingraylabs and at justingraylabs.com----------------------------------------- Help support the podcast ⁠www.patreon.com/withintolerancepodcast
June 8 · 2 hr 20 min
Within Tolerance Episode 278 - Post Summit Clarity with Zap
Two months of catching up with Zap: the Toolpath Summit recap, his Claude-built ERP CritLink processing real money, and his Boise shop dialed in for remote operation. Dylan finally has power, runs the Flex overnight, untangles a kinematic shift on the C250, and survives a titanium job that tried to take him out. Check out Zap's IG @zap.consulting ----------------------------------------- Help support the podcast www.patreon.com/withintolerancepodcast
May 1 · 1 hr 55 min
Within Tolerance Episode 277 - Matt Blackwell of Blackwell Engineering
Matt Blackwell spent over two decades fixing jets and flying C-17s before building a one-man backyard shop and a fiber laser fixture business he never planned on. We talk spindle gripping lessons, the messy line between hobby and business, and how a guy in a backyard shop ends up tapping a few hundred thousand holes. Check out Matt's IG @blackwell_engineering ----------------------------------------- Help support the podcast www.patreon.com/withintolerancepodcast
April 11 · 2 hr 44 min
Within Tolerance Episode 276 - Joseph Alonso of Novo Modo
Joe Alonso tells the full Novo Modo origin story—off-grid childhood, working full-time at 16, a career detour through blindness and Microsoft, and launching a shop on pure conviction with no customers lined up. We dig into his inspection-first approach, keeping shops small on purpose, and why culture fixes more than training ever will. Check out Joe's LinkedIn at linkedin.com/in/joseph-alonso-34874690Check out Novo Modo's IG @novomodomachining ----------------------------------------- Help support the podcast www.patreon.com/withintolerancepodcast
March 31 · 2 hr 29 min
Within Tolerance Episode 275 - Still Powerless with Zap
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 ----------------------------------------- Help support the podcast www.patreon.com/withintolerancepodcast
March 6 · 2 hr 40 min
Within Tolerance Episode 274 - Brian Kippen of KAD Models
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 ----------------------------------------- Help support the podcast www.patreon.com/withintolerancepodcast
February 13 · 2 hr 5 min
Within Tolerance Episode 273 - Wrapping Up 2025 With Zap
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 ----------------------------------------- Help support the podcast www.patreon.com/withintolerancepodcast
January 21 · 3 hr 32 min
Within Tolerance Episode 272 - Ethan Perrin
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 ----------------------------------------- Help support the podcast www.patreon.com/withintolerancepodcast
Dec 20, 2025 · 2 hr 18 min
Within Tolerance Episode 271 - Pre-Flexing with Zap
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 ----------------------------------------- Help support the podcast www.patreon.com/withintolerancepodcast
Nov 14, 2025 · 1 hr 43 min
Within Tolerance Episode 270 - Wait, You Take Breaks? With Zap
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 ----------------------------------------- Help support the podcast www.patreon.com/withintolerancepodcast
Oct 31, 2025 · 1 hr 55 min
Within Tolerance Episode 269 - Devin Bodony of Lichen Precision
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 ----------------------------------------- Help support the podcast www.patreon.com/withintolerancepodcast
Oct 22, 2025 · 1 hr 53 min
Within Tolerance Episode 268 - Curt Van Filipowski of Confounded Machine
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 ----------------------------------------- Help support the podcast www.patreon.com/withintolerancepodcast
Sep 19, 2025 · 1 hr 59 min
Within Tolerance Episode 267 - Jamie Peacock of JSpec Engineering
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 ----------------------------------------- Help support the podcast www.patreon.com/withintolerancepodcast

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