Firefighter Machinery Rescue Training Box

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Hey guys,I primarily design/manufacture training equipment for firefighters.This is a prototype of a new product I’m launching soon. The box is made to simulate a few obstacles one might encounter when dealing with a person who gets a limb stuck in heavy machinery and it has to be disassembled/cut apart to free them.It features 3 replaceable access panels which firefighters are expected to practice cutting/drilling and air chiseling through. A couple pillow block bearing rollers made of 3/4 round bar and boiler tube. A roller that can be cut out using 1/2” bolts as replaceable shafts. Sprocket on a roller chain that locks one of the rollers from moving until it’s released.A 160 lb spring loaded ram.And a few steel cutting holders for sawing through in tight spots.I also used 6 different styles of fasteners so guys couldn’t bring 1 socket to the table and access everything.Took about 16 hours total drawing and tweaking the CAD model which was then primarily CNC cut. The next version will look like the drawing, with tab and slot construction. The main box is 3/16” construction and the overall unit weighs 140 lbs to be fireman proof.This is by far the pinnacle of my Fusion 360 ability. It’s been a truly invaluable skill to learn.www.FirehouseFabricators.comZachLincoln 210mpLincoln SW200Hypertherm Powermax 45xp2x4 CNC Plasma Table.
Reply:Here are some shots of the first production unit i am currently working on now, with the tab and slot style assembly. Took me a good 2-3 hours to add in the tab design.www.FirehouseFabricators.comZachLincoln 210mpLincoln SW200Hypertherm Powermax 45xp2x4 CNC Plasma Table.
Reply:Im sure those tabs made assembly much easier. So what's the goal, remove all components so you have access to the other side? I can see it helpful to show how different tools would be used to remove obstacles. Around here they usually use junk cars and have at it with the hydraulics and saws.
Reply:Originally Posted by M J DIm sure those tabs made assembly much easier. So what's the goal, remove all components so you have access to the other side? I can see it helpful to show how different tools would be used to remove obstacles. Around here they usually use junk cars and have at it with the hydraulics and saws.
Reply:Very nice your time working out the tab and slot design was well spent, I sure you will find a place for them in future projects.  Looks like you may be looking for a larger shop soonDIY CNC Plasma table USB BOB Price THCHypertherm 65Everlast PowerTig 255 EXTMiler 180 Mig13" metal latheMill/ DrillECT, ECT,
Reply:Originally Posted by acourtjesterVery nice your time working out the tab and slot design was well spent, I sure you will find a place for them in future projects.  Looks like you may be looking for a larger shop soon
Reply:Originally Posted by BrooklynBravestWell sadly enough many of my generation and younger (im 30) just aren't... men anymore. They're not good with hand tools unless they work on cars or they're some form of tradesman.So this just gives them the ability to work with various tools in a confined/uncomfortable space. We go to the junk yard as well here to focus on automotive extrication but this is meant more to be a close quarters/finesse operation. Using smaller hand tools, lifting airbags, air powered saws/cutters/drills. You can set it up to tunnel from one side to the other or through any of the access panels. Really up to whoever is running the training scenario. There would be a prosthetic arm stuck in there but I can't get one with amazon delays.
Reply:Originally Posted by M J DI get that with mechanical ability and all. I'm sure that there are some out there that would see a simple wrench and figure it was something that they could use in a body piercing. As for the prosthetic arm, maybe a piece of pvc pipe will have to do for now
Reply:Does the roller with the chain drive actually turn while in use? I can see good and bad points for that. Do they use a sawzall or bolt cutters/hurst tools to cut the items?Any thoughts of rounding off the heads of the bolts so it it like an old machine? That way they also cant just throw a wrench on it and be done. Its kind of like the old "Operation" game  but for fire fighters.Its a great idea in a small package. Sent from my SM-G930V using TapatalkMillermatic 252 MIGMiller Dynasty 200DX TIGMiller Spectrum 625 PlasmaAltas 12x36 Metal LatheBridgeport Milling Machinewww.psacustomcreations.com
Reply:Originally Posted by psacustomcreationsDoes the roller with the chain drive actually turn while in use? I can see good and bad points for that. Do they use a sawzall or bolt cutters/hurst tools to cut the items?Any thoughts of rounding off the heads of the bolts so it it like an old machine? That way they also cant just throw a wrench on it and be done. Its kind of like the old "Operation" game  but for fire fighters.Its a great idea in a small package. Sent from my SM-G930V using Tapatalk
Reply:When drawing up the slot and tab on a project do you have a male and female template that you place as you go along. Or is each set drawn in each location separately?DIY CNC Plasma table USB BOB Price THCHypertherm 65Everlast PowerTig 255 EXTMiler 180 Mig13" metal latheMill/ DrillECT, ECT,
Reply:Originally Posted by acourtjesterWhen drawing up the slot and tab on a project do you have a male and female template that you place as you go along. Or is each set drawn in each location separately?
Reply:Very nice work. Prototype looks like a perfect duplicate of the original drawing. Nothing I ever made was that faithful to the caulk drawing on the face of my welding table or the scribble i drew on a 2x4.  Btw that  tab and slot construction is too cool, there must be no end to the possibilities.
Reply:Here’s a couple more.These are 1/4” the other two were 3/16”. It works best with at least 3/16” but i imagine 1/8” would be fine as well just less of a landing to weld.For the box it’s really a home run because welding the walls together inside is a challenge.These two had some lessons learned that you need the half circle over cut, to account for the inability of a plasma to make a perfect corner.www.FirehouseFabricators.comZachLincoln 210mpLincoln SW200Hypertherm Powermax 45xp2x4 CNC Plasma Table.
Reply:thanks for the reply, those projects show why it is great to have a CNC plasma in the shop.  The grit on the belt grinder look very hungry make short work on a manicureDIY CNC Plasma table USB BOB Price THCHypertherm 65Everlast PowerTig 255 EXTMiler 180 Mig13" metal latheMill/ DrillECT, ECT,
Reply:Originally Posted by acourtjesterthanks for the reply, those projects show why it is great to have a CNC plasma in the shop.  The grit on the belt grinder look very hungry make short work on a manicure
Reply:Belt grinder are very handy for the shop I have 2 a 2" X 60" I built many years ago, I cast the aluminum parts for it.  And the other is a Jeremy Schmidt 2" X 72" that I plasma cut the parts for. Attached ImagesDIY CNC Plasma table USB BOB Price THCHypertherm 65Everlast PowerTig 255 EXTMiler 180 Mig13" metal latheMill/ DrillECT, ECT,
Reply:Originally Posted by acourtjesterBelt grinder are very handy for the shop I have 2 a 2" X 60" I built many years ago, I cast the aluminum parts for it.  And the other is a Jeremy Schmidt 2" X 72" that I plasma cut the parts for.
Reply:They are not really pilot holes but dimples like center punches.  Here is a video of them being dimpled,  I setup the G-code with all the dimples first the a pause in the G-code.  I then increase the amps and do the finish cutting of all the parts.  I use a centering drill to start the hole drilling then the normal drill to finish, works great.  You can place them in the DXF file when you do the CAD work.It is a simple procedure I can give you the info for SheetCam.https://drive.google.com/file/d/13Bu...ew?usp=sharing Attached ImagesDIY CNC Plasma table USB BOB Price THCHypertherm 65Everlast PowerTig 255 EXTMiler 180 Mig13" metal latheMill/ DrillECT, ECT,
Reply:Originally Posted by acourtjesterBelt grinder are very handy for the shop I have 2 a 2" X 60" I built many years ago, I cast the aluminum parts for it.  And the other is a Jeremy Schmidt 2" X 72" that I plasma cut the parts for.
Reply:If it interests anyone tested it out doing a couple scenarios at work the other day.One was just a simple hand crushed/stuck under weight. The other we did an impalement and made guys cut access, and work in the tight space to cut the rod.Our main focus when we do any of this stuff is causing the least amount of excess harm. Using tools that cause sparks or vibration are generally a delicate/risky operation as we don't want to burn the victim on top of their situation and limiting movement of the impaled object will control excess bleeding.Last edited by BrooklynBravest; 05-05-2020 at 08:29 AM.www.FirehouseFabricators.comZachLincoln 210mpLincoln SW200Hypertherm Powermax 45xp2x4 CNC Plasma Table.
Reply:Nice work. I need to pick your brain on tab and slat set up. I need to learn how to do this with my cnc plasma too.Thanks.T.J.www.tjsperformance.comDynasty 300 DXHTP 240HTP Microcut 380Hyperthem 85JD2 Hyd Bender and HF Hyd Ring Roller all in one =(Frankenbender)Bpt. Mill/DRO4' x 8' CNC Plasma TableInstagram: tjsperformanceYT: TJS Welding and Fabrication
Reply:Not to step on BrooklynBravest toes but I decided to work out a template for those that want to use the slot and tab for joining plates.  This is the first cut after drawing what I though would work, I made a slight calculation error which I trimmed off so the fit together.  The plans is to have 2 DXF files that can be copied and pasted into a drawn project and positioned so they connect with each other as to how many and where.https://drive.google.com/file/d/1J18...ew?usp=sharing Attached ImagesDIY CNC Plasma table USB BOB Price THCHypertherm 65Everlast PowerTig 255 EXTMiler 180 Mig13" metal latheMill/ DrillECT, ECT,
Reply:Originally Posted by acourtjesterNot to step on BrooklynBravest toes but I decided to work out a template for those that want to use the slot and tab for joining plates.  This is the first cut after drawing what I though would work, I made a slight calculation error which I trimmed off so the fit together.  The plans is to have 2 DXF files that can be copied and pasted into a drawn project and positioned so they connect with each other as to how many and where.https://drive.google.com/file/d/1J18...ew?usp=sharing
Reply:Originally Posted by BrooklynBravestGreat idea. TJ was working on figuring it out in Inkscape and I had no idea how to do it. I'm a fusion man.Originally Posted by BrooklynBravestWell sadly enough many of my generation and younger (im 30) just aren't... mechanically inclined men anymore. They're not good with hand tools unless they work on cars or they're some form of tradesman.So this just gives them the ability to work with various tools in a confined/uncomfortable space.
Reply:Does this box really work?And what's wrong with the fact that there will be one less subject in school?Last edited by palumanyc; 3 Days Ago at 06:06 PM.
Reply:Of course it works.The problem is that this subject was significant. In many schools, the subject where children studied the structure of motors on the example of a car or motorcycle was removed. I think it's terrible because now all young drivers do not even know what they are driving. Firefighters should be well versed in cars and safety. My friend works as a firefighter and sends to everyone the rules of behavior in case of a fire or when firefighters arrive. Children aren't told about this at school now, and it's a pity.
Reply:Haven't been on the forum in a while.Its worked out well and have sold around 40 of them since this post was made. It has evolved a little bit over that time too.www.FirehouseFabricators.comZachLincoln 210mpLincoln SW200Hypertherm Powermax 45xp2x4 CNC Plasma Table.
Reply:Also selling this mock meat grinder prop as well now for departments with lesser budgets available. It has a www.FirehouseFabricators.comZachLincoln 210mpLincoln SW200Hypertherm Powermax 45xp2x4 CNC Plasma Table.
Reply:Zach,I would also like to buy a dxf file of the Harbor Freight press brake mods for the lower die. You have several people wanting them lately. PatMillermatic 252 MIGMiller Dynasty 200DX TIGMiller Spectrum 625 PlasmaAltas 12x36 Metal LatheBridgeport Milling Machinewww.psacustomcreations.com
Reply:I'm horrified by these photos with fake hands. Of course, I know that this is just for training. It's just that the fact that someone can cripple their hand like that scares me. This will no longer be a joke. That's why you need to go through a training school. There it becomes clear who will be accepted for this job and who will not. After all, you need to have solid nerves for it, and you can not be too impressionable. It's essential to know that human lives depend on calmness and confidence. I have read so many times about the importance of learning on this site firerecruitmentaustralia.com.au, but I haven't seen such photos.