In this week’s episode, Beau chats with self-taught fabricator and structural engineer Jake LeGrand about his journey from college research labs to hand-cutting custom metal signs and flatbeds in his Kansas City–area shop. Jake shares how learning a broad range of skills—from plasma cutting to welding—opened new doors and fueled his passion for “collecting” techniques. If you’ve been curious about taking on sign-making, turning your hobby into paid work, or just leveling up your fabrication game, this episode is for you.
In This Episode, You’ll Learn:
1. Jake’s Beginnings
• How a college job in a research lab led Jake to discover a love for welding and fabrication.
• The crucial first “yes” moments that sparked his passion for fabrication.
2. From Hobby to Side Business
• Making pheasant silhouettes and farm signs for friends and professors—and how word-of-mouth grew his clientele.
• Balancing a day job as a structural engineer with an after-hours metalworking hustle.
3. All About Plasma Cutting
• Going from a compact Hobart unit with an internal compressor to setting up a larger shop space.
• Why dry air and proper equipment maintenance can save you money on consumables.
• Hand-cutting vs. CNC: Why Jake still loves the artistry and freedom of freehand plasma cutting.
4. Building Large-Scale Projects & Shipping
• Creating oversized signs and the shipping challenges that come with them (including freight costs and oversize fees).
• Safety tips for cutting into tanks, including thorough cleaning and venting.
5. Sign-Making Logistics
• How Jake sketches sign designs using an iPad and overhead projector to achieve accurate proportions.
• Lighting options (like Govee LED strips) for durable, easy-to-control sign backlighting.
• Simple mounting solutions that help customers install heavy metal signs.
6. Tool Talk & New Adventures
• Jake’s recent partnership with ESAB and how it aligns with his preference for genuine, “non-salesy” endorsements.
• Venturing into building custom truck flatbeds and the opportunities on social media platforms (like TikTok) for new projects.
7. Mindset & Advice for New Fabricators
• Keeping the passion alive and avoiding burnout: why loving what you do is key.
• The importance of doing your own research and respecting others’ time when asking for help.
• Embracing a “skills collector” mentality—never know which skill you’ll need next!
Connect with Jake
• Instagram: @LeGrandMetalWorks
• TikTok: @LeGrandMetalWorks
• Facebook: LMW LeGrand Metal Works
• YouTube: LeGrand Metal Works (Shorts & upcoming full-length project videos)
Thank You To Our Trusted Partners
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Email - [email protected]
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