Mini-chopper project builds on real-world challenges

Teams of students compete in mini-chopper fabrication

By Charlie Mathews, Herald Times Reporter

MANITOWOC — Parts may be measured incorrectly or delayed in arrival. Assembly diagrams may be confusing. Getting everybody on the same page may be difficult.

Welcome to the real world, Jill Hennessey told the five teams building downsized motorcycles as part of the second year of the Manitowoc County High School Manufacturing Project.

"We want to make it challenging, but not frustrating," said Hennessey, manager of talent acquisition for The Manitowoc Company, said of Project Mini-Chopper.

Its subsidiary, Manitowoc Ice, is one of five lead sponsors, along with Manitowoc Tool & Machining, Heavy Metal Fabricators, Baileigh Industrial and Lakeshore Technical College.

"I've learned a lot about engines and building frames," said A.J. Kenneke, a senior and captain of the Valders High School team.

"We get hung up once in a while when something breaks down. But, once or twice, it's been like, 'One, two, three, holy cow, we got that far!'" Kenneke said of the machines set to debut April 23 at the Ant Hill Mob's
annual motorcycle show.

Teammate Logan Figueroa said the squad appreciates the assistance of Baileigh's John Newberg and the use of the company's metal bending equipment.

Remaining challenges? "I'm thinking fenders and electrical … no one has any idea how to make fenders but we'll figure it out," Figueroa said.

In addition to Valders, two Lincoln High School teams are fabricating mini-choppers, with others under construction by Mishicot and Valders, and one from various class environments in the Manitowoc School District.

The five teams recently presented progress reports identifying issues and challenges, work completed, how their sponsor's brand is incorporated into the mini-choppers' designs and a review of how their $2,500 budgets have been spent so far.

Technical skills and more

Officials of The Chamber of Manitowoc County and the Economic Development Corporation of Manitowoc said they co-sponsor Project Mini-Chopper to improve the image of manufacturing.

Organizers said the manufacturing sector continues as a vital employer in Manitowoc County, with about 30 percent of the jobs.

Specifically, they want students, parents, educators and the community to understand that manufacturing offers excellent career opportunities today and in the future.

Hennessey and Karen Szyman of the Chamber wrote a review of the first year of the program that included teams from Lincoln, Valders and Roncalli.

They said students learn a variety of skills including mechanical design, welding, painting, budget and project management, electro-mechanical, quality control, safety, marketing, public speaking, time management and information technology.

Not all students learn every skill. Ben Cisler is on the Valders team and said some of his fellow students are more proficient at cutting and welding.

Cisler said he pitches design ideas using "SolidWorks" software and helps update the team's Web site.

The team's faculty advisor is Jacob Haag, in his first year as a technical education teacher at Valders. "I'm learning about getting all the kids on the same page," said Haag, who previously taught at Two Rivers High School.

"You feel rushed no matter what you do," said Clayton Nei, a tech education instructor at Lincoln. "It's just the nature of the project."

David Wage, Heavy Metal Fabricators president, wondered whether a handbook could be developed describing what local companies will do — for example, metal bending, painting parts — on a free or reduced rate as an in-kind service.

Hennessey said a few tips handed down to succeeding years' teams might be appropriate and appreciated.
But, part of the learning process is having students understand to make contacts to find services and parts.

"We don't want to spoon feed too much," she said.

Wage said he enjoyed hearing reports "from these talented youth. It is important to support the trades and not just those going on to universities."

Influenced academic path

Joe Vogel, a mechanical design freshman at Lakeshore Technical College, was on Roncalli's team last year.

"Being on the mini-chopper team helped me decide what I'm going to do," said Vogel, who plans to transfer to University of Wisconsin-Stout after two years at LTC. He said his welding skills were strengthened.

"I had a blast," said Will Clark, a teammate of Vogel's and a freshman at LTC in auto maintenance. After a second year at the tech college, Clark said he wants to be a mechanic and purchase his own shop one day.

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