Old ZDS workshop tour [ZDSPB Store]

Old ZDS workshop tour

This page shows my old paintball workshop used between 2003-2007 when I was running the ZDS marker repair shop. At the time, this page was available as a "shop tour" so players could see where their equipment would end up after sending into me for work.

At its peak, the ZDS repair shop serviced around 500 repairs in one year (2006). Not all of those shipments were entire markers, as some were simply circuit boards or other small marker parts, but regardless I was completing a lot of repairs during this timeframe.

The workshop was located in the basement of my house at the time, located in Adrian Michigan. Eventually the shop became organized into these areas;
1. Marker testing workbench (main repair area)
2. Electronics workbench
3. Modification / project area
4. Marker storage bench

I didn't have a good digital camera during this time, so pictures and videos are rare. Remember this was before phone cameras! Despite the technology problems, I was able to retrieve some good pictures to show (below).

Testing bench:
This was the primary area where markers were serviced and tested, also including the process of disassembly and reassembly. Most markers were cleaned, tuned, and adjusted in this space which was the head of my marker storage area (next to the electronics bench). If a marker required more time to repair, or if I needed to communicate with the owner, I would move the individual marker components out to the storage workbench to get it out of the way while another repair could be made for somebody else.

Reassembly/testing bench

While not seen in any pictures, I tried to keep just about all required testing hardware available for most paintball equipment. The goal was to avoid sending barrels, tanks, lubricant, or other equipment because I could use my own test items to work. This also included retaining spares for the most common markers (to aid in the diagnosis process). Only the obscure markers would need special shipments of their own spare parts.

Spare parts bench

Marker storage:
If needed, loose marker parts would be moved out from the main workstation and into a general storage area to await further repairs or other work. Typically I would not bother reassembling a marker just to take it apart again the next day, which explains why all my pictures of markers in the storage area were disassembled. This long countertop could hold nearly a dozen markers in varying states of repair; awaiting diagnosis, waiting for communication with the owner, waiting for loctite to cure, waiting for replacement parts to arrive, etc.

Marker storage

Marker storage 2005

Marker storage 2004

Having the physical space to house markers within the shop was a large factor that allowed my repair business to thrive during its time. Logistically, any type of repair service involves a fair amount of coordination to track items within the shop while the work is being performed. Running out of space is very easy, so continued growth of a service-based business will quickly encounter that problem.
To track the markers, I used printed "work order" info sheets that contained all necessary information on the equipment owner and the scope of work being performed. These info sheets are also known as "travelers" in most industries, since they travel around the shop with the items.

Once a marker was finished, I would package it up and move to the shipping area while awaiting payment. When shipping the marker, many players would send it in the original box for good packaging, but this wasn't required.

Marker boxes awaiting payment

Electronics bench:
Specialized repair and mods that involve soldering would occur in this area. Assorted replacement components (switches, LEDs, semiconductors) and testing equipment are stored in the organizer drawers seen in the photo below. I had to make a mosiac picture to show the entire bench. Initially, electronics repairs and modifications formed the backbone of my repair shop, because damaged switches and wires were extremely common in those days.

Soldering bench

Countertop workstations

This area of the shop was often seen in the website's tech articles since the white countertop made an excellent background for photos. However, the electronics bench wasn't often used for other repair work since it was further away from the spares.

Project and modification benches:
A separate area contained project markers that would be in the shop for longer periods of time. Markers within this category were often sent in for an electronics retrofit to allow them use of another circuit board, or perhaps some other type of detailed customization. This workbench was effectively a long-term storage area because markers located here would be in the shop for more than a month.

Long-term project storage bench

Two Shocker SFTs undergoing Morlock board retrofits

My initial jump into the metalwork hobby began with a small drill press, mini-lathe, and mini-mill. These items were all "benchtop" category and were the cheapest of the cheap, but they got the job done. The equipment was initially used for repairs, but soon I realized how effective (and fun) it was to make replacement components to help expedite repairs. Eventually I began experimenting with new scratch-built components using the same rudimentary manual equipment. Good components can still be made on junk equipment so long as you're experienced enough to work within the limitations of the junk. (although it will be much easier with good equipment!)

Mini-lathe bolt modification

Drill press counterboring

What happened to the ZDS repair shop?
The answer is fairly straightforward - In 2007 I realized that my business was growing steadily and I was going to run out of capacity within the next year, if not sooner. Despite being very fun and enjoyable, realistically I wasn't making much money compared to the amount of time that was spent in the shop (LOTS). I knew the next course of action was to expand the business into other areas, such as anodizing or more professional milling. Another option was to join forces with an established paintball proshop to work under their roof, but there weren't any shops in my area.

Another problem arose; I moved away from this house in 2007, and my new apartment didn't have the space to store markers and repair them on a daily basis. For this reason that I closed the marker repair operation in Fall 2007 while simultaneously enrolling at a nearby technical school. I wanted to learn more about CNC manufacturing and knew I wouldn't be able to learn it alone.

I attended school from 2007-2009, but my first job in the industry was not in manufacturing but instead within the industrial robotics industry. It wasn't until later that I was pulled back into the machining world. In 2010 I created the company Nummech Products to build and market paintball accessories for some of my favorite markers. I bought fabrication equipment of my own and now run a small-scale machine shop with equipment that far outclasses the humble ZDS basement repair shop. Most of the items found on my Custom Work Gallery were done either in my ZDS basement repair shop between 2004-2006, or at the Nummech Products manufacturing facility between 2011-present.

A detailed view of my current machine shop can be found on the Manufacturing in paintball page for Nummech Products.