How I made steel toe crocs with wood 

Heads up: I'm not the first person to do try to do this - if you want to be entertained with some good lulz you should check out the OG steel toed crocs from I did a thing: ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-29iC6RlbL7s.html

Mate, we should have a dance off!

*at job interview* "Oh I heard you've done some projects of your own! Care to share them?" *Lifts foot into table* S t e e l - t o e d c r o c s

The key to avoid the folding is to make it in steps, increasing the depth of the mold each time. I think there is even theoretical formula to know how many steps you have to do.

I'm so addicted to this channel. The fact that failure is the process helps me in my every day life. Everything about the format of this channel is amazing. Thank you

Nice Shane! Great to see the whole learning process.

"I never claimed to know what I'm doing... I just know what I'm trying to do" Oddly profound. I like it

It's really interesting to look back at this video from just a few years ago and note how much Shane has built up his chops as, honestly, an entertainer.

I used to work in an automotive press shop. We made parts for BMW. From my experience I can tell you that pressing the part in one go is not the best method. The way the presses worked in the automotive field is that they used a step method. The part was stamped out bit by bit using large rolls of sheet metal. The stamp would come down on one part of the metal & make a shape into it. Then the moulds would open up on top & bottom & the sheet metal would me moved along to the next stamp. So on & so forth until the final part was clipped off at the end of the run. This would prevent the metal from buckling & would provide a nice consistent form The extra scraps of metal would fall off into a conveyor system where it would be routed to a metal collection bin that would then be remelted & reformed into new sheets of metal. Nothing went to waste.

"I never claimed to know what I'm doin'. I just know what I'm trying to do." Words to live by 😂

3:06 "it took me four or five generations to get this tool mostly working" _the project had begun with my grandfather's grandfather... we know no longer why we toil in the fabrication of this instrument so hideous, but such is our charge_

@16:40 Love that line, "I never claim to know what I'm doing, I just know what I'm trying to do." You've summed up almost everything I've ever done.

I love that you make engineering look so attainable to the average mind. You show that it’s okay to fail (so long as you have the materials lol) and that with the right attitude, you can make anything

"I've now succeeded in making 2, pretty ugly pieces of garbage" yeah my mum said the same thing.

when that weight fell off at the shelf at 0:17 , I instinctively moved my foot and stubbed my toe into my desk...

As a mechanical engineer, I think it's pretty cool to see how you iteratively come to a process that's very similar to standard drawing and forming presses! Especially that hold-down plate to prevent material bunching up during the drawing step. Kudos! 😀👊🛠️

I love how this channel is the epitome of overengineering. Mid-video I realised this would probably take a few hours for a blacksmith to make.

when he realizes he has to make another tool for the left foot

"Projects are the star of the show, I'm just the host." That is probably the best quote ever

wait until he finally realizes he has to make a left croc

This was very interesting to watch, especially as a tool and die maker! Loved watching the trial and error! It's honestly the best way to learn. Draw dies are definitely the most complicated dies to design! Impressive even more still as you were able to accomplish this using wood! Love this channel! I think I've watched all your videos now! Looking forward to seeing what's next!

"Can wood form steel?" Blacksmiths making armor a few centuries ago: 🤨

This guy is literally the personification of: "How old are you? Between 7 and 37"

One of the easiest ways to help control the buckling or wrinkles is to remove material from the area. Put a semi-circular cut-out in the areas with the wrinkling. Less material in the area of the wrinkling gives all that "extra" material somewhere to go with folding over. Experiment with how big the semi-circle should be to make sure that the edge of the circle isn't pulled into a part of the final shape that you care about. Depending on the exact contour, this may lead to the wrinkles forming in the toe portion rather than the clamped area. As Matthias mentioned, draw beads are a huge help in cases like this, especially since you have the capability to machine them in. Since the bead touches the sheet metal first, as you clamp the die together it will hold that area in place and force more of the surrounding metal into the form. This helps spread the distribution of material that you're pulling so that it's not just all the "easy" material at the wrinkle point. More resistance to movement means less flow of material, but be careful not to clamp it too severely or the sheet metal will neck down and eventually split.

7:22 “I’ll leave it as an exercise to the viewer” sudden ptsd from college textbooks

Next video: "Crocs™ sued me for 7million dollars"

Why did I watch this? RU-vid: Did you enjoy it? Well, yes... but... RU-vid: You're Welcome.

Engineering decision making 101: Why is the plate 16 gauge? Well, my wife was asleep

I love seeing your iterative process, and I totally relate with this sort of side project that is maybe a little bit useless, but still teaches you a lot about a process that you can carry forward.

“ I don’t know what I’m doing, I just know what I’m trying to do.” Needs to be on a shirt yesterday 😂😂

Outta take a gander at ‘I Did A Thing’ and his steel toed crocs

YOU are the star of the show! You literally make everything happen and escalate it to a higher level its just amazing 👏 love your videos never stop 😇

11:05 , 13:48 , 16:16 , 17:38 love watching the creases form. Its so cool to think how many things deform in this way- clothing when you bend your knees and elbows, towles hanging on a rack, paper you crumple up, etc; all follow the pattern of buckling/folding. I guess this must be the cheapest way for the universe to deform flat surfaces or something? Its so cool

I'm surprised no one in the comments has mentioned "draw beads". Draw beads are bumps overwhich the metal is pulled on the edge of the form to put resistance to pulling it in. Not stop it from pulling it in, just resistance, so that the metal is under a lot of tension, which helps it stretch better without wrinkling. Go look it up. As a student, I once worked in a research lab that investigated the effect of different lubricants on draw bead friction. The auto industry spends a lot of money on this.

Faceless is fine to me 🤷🏾‍♂️ Your projects are stars on their own. I call you The Young This Old Tony. Keep going.

I’m just a lowly woodworker, but my engineering degree helps me see the genius in this man. You sir, are inspirational. Also, the way you include your wife gets the approval of my wife, and now she watches with me. Thanks for sharing. My kids will be shown you as an example of how cool it can be to be smart and capable with your hands.

Great job Shane! This was super interesting being able to watch the entire process.

Literally every comment from the hoop video: “you should mass produce this” This guy: “I’m going to mass produce steel toed crocs”

Remember this guy when he spent his days mass producing steel toed crocs, and I was here to watch along. See you when you hit a mil subs.

I did pneumatic forming with wooden forms in my college metalworking class. Annealing the metal, bolting it to the form, and then hardening it afterwards makes the process SO much easier. That lets the metal actually stretch and form, and then you can harden and temper it however you want at the end.

I think it's hilarious that your wife makes all these things and you take the credit for it.

"i want to wear my crocs in the shop and not smash my feet" me: "OMG Finally, I'm not alone!"

Your problem-solving skills are really impressive, it would be cool if you could share more of your background (how you learned all of this, if you studied at university, etc.)!

You are so right about this part 15:32. In designing stuff you have to ambrace failure. I know it can be hard for some but I would say to become a good designer in general one must to learn to fail fast to get to the end goal. We shouldn’t spend too much time trying to think if the prototypes along the way are finished or not becouse we just want the end product to work. Embracing failure is one of the ten design heuristics I live by and apply it to my own business

the projects dont exist without you soyou are actually the star.

8:42 my parents after having me as their second child

Nice work. Lesson to be learned from WWI. German helmets stopped bullets. Ours did not. Multiple pressings. Each going a little deeper, each time. Plus soapy water. This led to a more even wall thickness. So bullets to the forehead, temples, etc .... were stopped. Maybe that would fix your issue w/ folding/bunching up. I look forward to seeing more of your work!

The first form dies were made out of wood, and they were used in smith shops. It could be argued that the first mass production elements (scaled for the day) were made in there.

19:48 I'm too weak, and my wife's asleep, so... 😂

"I'm not made of money" **has his own CNC mill**

The sad part is that each tool is only for a right croc

3 things you might want to look into the next time: blank shape has a big impact (doesn't need to be square - might be squiggly shaped). To get rid of wrinkles, you want to stretch the material OUTSIDE of the final part you want to make. Blank holding is actually quite important (draw beads, clamp force, bla bla bla). I love how you got actually nice quality parts from such a simple tool . I really really like how you get to your result and that you show the iterations.

Yes my wife and I think you are doing great and enjoy when you show your face to the camera. Thank you for what you are doing

You are what I want to be when I grow up. I'm 24

I have a even worse idea: Full metal crocs.

Genuinely one of the most endearing creators on engineering yt

Cool! Been wearing Bistro line Crocks for over 13 years!!! great stuff!!!! I would definitely want those for work!

I dreamed about steel toe Crocs since I first started wearing them in the shop. I can't believe I'm not alone. Will definitely buy ones..

"Metal really likes the shape that it is" Very inspiring, good for metal

Hes changed so much in the last year

Your videos are fantastic, I really appreciate them. Thank you!

Die design is a fickle beast. Easily as much art and intuition as science. I must commend you. You have wrapped your head around draw die concepts that take years for some die design engineers to grasp. And you’ve done it with a Chinese press and some scraps of wood!! As far as showing your face on camera...I’d say whatever makes you more comfortable and doesn’t interrupt you workflow too bad.

I come from aircraft engineering so I’m more of an aluminum guy, but we would typically use annealed stock for a formed part with radii that tight, and then use the work hardening itself or tempering to hit specs. I’d reason that you would still run into some issues if you fully annealed the stock at the start just based off the gauge you’re going with, but if you started with an initial rig that is similar to what you have going, I’d say you could take it three quarters the way to your ideal shape and avoid buckling. From there you could trim to your final dimensions, hit it with a quick torch anneal (benefits of it seeing a croc and not an aircraft haha), and then pop it into a final forming block (a registration pattern of some sort would be helpful) that would set your final dimensions and work harden it back to steel toe territory. Would hopefully avoid a lot of springback related calculations, and would mostly just give you an excuse to put a mirror polish on those bad boys! Anyways, just figured I’d throw my hat into the ring! Who doesn’t love a little armchair manufacturing engineering? 😂 Love the videos!

i cant believe no one ever told you to take a torch and HEAT UP THE METAL. makes it waaaaaay more malleable.

Just discovered this channel. Love the content and energy.

i know this video is months old and you may not read these, but i appreciate when you look into the camera while explaining something because it seems easier to focus on what you're explaining

I absolutely loved that you interrupted "made of money" with an ad. That's amazing XD

I really do adore this man's tenacity. However I can't believe there's a human being on this planet so committed to crocs.

Yeeeeeeeees! I finally found the video where you say what app you use to draw stuff. Man I looked for this a long time.

I like the no face “ala young tony” style. And also like this old tony videos I watched the whole 24 minute with a smile. Even tho I don’t know why, it’s a asset for a croc for f*ck sake. Great work

So I make my own custom bending and forming jigs out of steel for mass production.. this is really exciting seeing how someone else makes their forms.. the more you make these forms it will become second nature where it usually works after the initial idea..

the indent for the steel wa genious and the massive wood design, it was amasing fit

As a professional RU-vid viewer, I really like how you do the mini-videos at the bottom to show us the minor tasks (like 14:45). You have a very good intuition about video pacing to keep our attention.

I legitimately moved my right leg out of the way when he dropped the weight on his

I would pay large sums of money 💰 for this as a commercial product. I'd love to see a part two!

You might try annealing the metal before pressing it into the form. The metal will stiffen up as soon it is pressed into the form.

“What are the holes in crocs for?” “That’s where your dignity leaks out.” Stuff made here guy: “Oh ya. Watch this”

So what you are doing is soft forming.... in a way, just a tip, your "tool" is pt so its harder than your punch, the crop form in other words. Add a 90° bend to the outside of the stock use that bend as a clamping area that will force the material to stretch rather than pull. If the material pulls you'll have some good and some bad parts. Try AMS 5510 around 30 thousands. With my suggested method in combo with your methods you should have a 25-27. Thousands thick steel toe. I did a lot of forming,machining, and sheet metal work but thus I enjoyed the video! One more recommendation is pick 2 different materials. One vastly stronger than the other. I recommend using pressure treated for the punch, and steel for the tool. Ideally heat treat your tool steel to prevent wear and tear

hahah i kinda was thinking already it would fold in between that little crack when you went with all steel plates. Pretty cool project!

I just came here from the Robot Chainsaw Death Machine video. Aside from trying to figure out how you go from looking 19 in 2020 to married with kid #2 on the way in 2021, I'm really enjoying the content. I'm also a big fan of "Use the tools to have to make the tool you need." Great work; keep it up! (Also, the videos are a lot more fun when engage with the audience. The new format is great.)

Is no one going to talk about the poptarts just sitting on the table. That's the most genuine part of this whole project.

Didn’t “I did a thing” also make steel toed crocs?

Some thoughts I had mid way through the video: Would it be of any use to prototype molds with thinner gauge metal, or even aluminum foil? Perhaps adding some relief cuts in the blank would remedy the “bunching up” problem Maybe you could try forming metal preheated in an oven or use annealed stock

I've made (heavy) fiberglass dies to do steel and aluminum pressings. I've pressed pieces up to two square feet. I have a large-platen 100 ton press. It's mostly a matter of location and keeping the material in place with pins. One thing that makes the pressing easier is to use low strength "tryout" steel. Only about 30kpsi yield, so it forms easily.

Plot twist: He's actually using an aging filter the whole time. 1:00 is his real face and age.

"the novelty factor might be worth it - is a smart mans way of saying, lets do it for the memes"

The best hands on RU-vid are the hands of "This Old Tony".

Thanks for sharing this, I really enjoyed watching the iterations you went through. Thanks again much appreciated. What if something happened to fall and land at the back edge of the steel, could (or would) it fold down into your croc/foot? How heavy would something have to be for that to happen? I’m interested because I have a cautionary tale. I was in a shared art studio with several people working on different metal sculptures and related projects. Everyone was meant to be wearing steel capped boots (made to the Australian safety standards), but one dude had purchased a cheap pair. So anyway, he was cutting a big sheet of metal with a gas-axe, had the piece to be removed hanging over the edge of the workbench and….yeah, that large piece of metal (about an inch thick and approx 2foot x 1 foot) it fell down and landed right on the back edge of the steel toe, the steel toe insert bent down and cut into his foot, sliced off 2 toes and almost severed the others. It was a great day for everyone obviously 🙄. Long story short (er) Everything was (kinda) okay in the end, lots (and lots) of blood and lots of tools in the studio available for the paramedics to cut off the boot (Gag) And off to the hospital with toes in a bag that were then put inside another bag filled with ice. All toes except for one were saved. Soooo, LESSON LEARNT. Don’t be a cheapskate with safety gear…just don’t..NO. Also - Safety was drastically improved, footwear inspected prior to ANY studio access. No appropriate footwear, no access. Apologies for the overshare, but the mention of steel toes, always makes me think about that damn “back edge” and it’s guillotine potential - awesome I know. 🙂🐿

Hello, i may be a little late on this comment, but on your wooden press, wood is realy good at handelling compression, as long as the compression happends in the dirrection of the grains, think of them like a bundle of matches, if you press down on the tip of a match, it wont brake that easy, but if you press down at the side of a match it snaps. its the same thing with the wood itself. So if you try to mass produce steel toad crocks in a wooden press, keep that in mind.

When he did the "Continue in part 2" I quickly went to check if he posted it already.. yeah I got pranked..

Moving the probe in local space, is key. “Are You Local People”😂😂

Fascinating video. Would love to see you make a suit or armor with the same general thought process/techniques

"Does it look like I'm made of money..." cuts to ad lmaoooo I love that😂

One suggestion: You could design it so that you purposefully allow crumpling to happen at the back end (the part that you are going to cut off anyway) so that all the pressure will be dissipated to that spot making the parts that matter crumple less.

As someone who left an engineering path to pursue custom fabrication, I really enjoy watching your approach and perspective. Couple of insights from my experience, in case they might be helpful - MDF to make your bucks. It's much more predictable, leaves a better surface on thin/soft, and just the right amount of conformity on the edge for

this video is great inspiration for me to continue working on my projects!!!

You've discovered exactly why we don't use wood for metal forming lol

I had a lot of similar learnings here when I was doing my first upholstery. Wrapping fabric around a surface curved multiple directions has similar challenges with bending. The solution there was to cut triangles all the way up to the edge of the fabric, which allowed for the material to bend different ways without folding over on itself. I’d be curious if making a similar cutout in the metal blanks would allow the same here, potentially reduce the number of shaping steps required.

Great content bro! Keep up the amazing work!

"So I'm going to use my Tormach as a poor man cmm"