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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27 episodes
Avg 1 hr 49 min
English

Episodes 27

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November 6 · 1 hr 20 min
Down The Rabbit Hole with Justin Gray EP6 - David McHenry of Rego-Fix
David McHenry of Rego-Fix joins Justin to dig into the engineering behind tool holders. They cover micro friction damping, why collet surface finish affects runout, and how hydraulic, shrink fit, and powRgrip compare. Plus, why the biggest tool holder isn't always the best one.Check out Justin's IG @justingraylabsCheck out Rego-Fix's IG @regofix_group-----------------------------------------Help support the podcast www.patreon.com/withintolerancepodcast
November 5 · 2 hr 17 min
Within Tolerance Episode 286 - The Post IMTS Plague with Zap
Our first catch-up since IMTS. Zap survives the post-show plague and a truck fire, Kinematic Sauce picks up a distributor, and Dylan gets the shop ready for a CMM. Then we dig into Patreon questions on the best and worst of IMTS, horizontals vs. five-axis, center of rotation programming, and automating first-run parts. Plus, why a clapped-out Fox Body beats a fresh build at the track.Check out Zap's IG @zap.consulting-----------------------------------------Help support the podcast www.patreon.com/withintolerancepodcast
October 9 · 1 hr 37 min
Within Tolerance Episode 285 - Chris Townsend of Eagle Manufacturing
Chris Townsend joins me to talk about Eagle Manufacturing, the student-run business at Brown County High School in Indiana. We get into running a real shop with 70 students working short class-period shifts, using ProShop to keep handoffs on track, and giving kids room to fail safely. Plus, why a flat top grill might be the best culture investment in the program.Check out Eagle Manufacturing's IG @bceaglemfg-----------------------------------------Help support the podcast www.patreon.com/withintolerancepodcast
October 7 · 37 min
Down the Rabbit Hole with Justin Gray EP5 - The System of Systems
Episode five of My Tool Library Is Better Than Yours. If your shop runs on a standard tool library, those tools need to always be there. Justin and Zap break down Kanban cards, tool tags, and tool storage. Sometimes the answer is a better system. Sometimes it's just more holders.Check out Justin's IG @justingraylabsCheck out Zap's IG @zap.consulting-----------------------------------------Help support the podcast www.patreon.com/withintolerancepodcast
September 26 · 1 hr 40 min
Within Tolerance Episode 284 - The Sea of Kern - IMTS 2026
Everyone's answer for the best part of IMTS 2026 was the same: the people. Zap, Justin, John Grimsmo, Chris Hopkins, Andrew Henry, and James Meyette join me across four days of mini episodes, recorded from the Kennametal, Rego-Fix, Datron, and Matsuura booths, to talk about what caught their eye. We get into less AI hype than expected, metrology finds in the back rows, high-density workholding done the crawl-walk-run way, and the unglamorous side of running automation overnight. We also talk about a very special knife reveal and a packed meetup, with a massive thanks to Kern for hosting!Check out Zap's IG @zap.consultingCheck out Justin's IG @justingraylabsCheck out Andrew's IG @henryholsters Check out James' IG @cncappsjames Check out Chris' IG @chopkinsmax Massive thanks again to @kernprecision for providing a wonderful place again for the meetup and to @datroncnc @matsuurausa @regofix_group and @kennametal for allowing us to record in their booths! -----------------------------------------Help support the podcast www.patreon.com/withintolerancepodcast
September 5 · 2 hr 10 min
Within Tolerance Episode 283 - 5 Years of Change With Andrew Henry
Andrew Henry of Henry Holsters is back after nearly five years, and a lot has changed: 11 employees to just over 30, a building addition, a Matsuura MX-420, and a shift from making parts to running the whole stack for other holster brands. We get into hiring his first real programmer and handing over the keys, the dark side of lean and why gratitude has to come with it, bringing on a fractional CFO, and why you should set up a line of credit before you need one. Plus the one-button shipping software they built that pushed 1,100 orders in a single day.Shipster Pro: https://shipsterpro.com Nicholas Means- "How to Crash an Airplane": https://www.youtube.com/watch?v=099cHWSbAL8 Check out Andrew's IG @henryholstersand check out his podcast Lean Built: Manufacturing Freedom https://open.spotify.com/show/6GjYm11Mo4vwWRzzdY1hQ8?si=b5a70c7bdc474642 -----------------------------------------Help support the podcast at www.patreon.com/withintolerancepodcast
August 28 · 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

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