Welding students at Four Rivers Career Center recently put their skills to the test - and into action - by completing a real-world project that benefited a neighboring school community.

Under the direction of welding instructors Dan Kemper and Tim Bruckerhoff, a group of students successfully fabricated and installed a brand-new metal step to replace a rusted-out one on a St. Francis Borgia school bus. The project combined technical skill, teamwork, and problem-solving - all key aspects of the program’s hands-on learning approach.

The opportunity began earlier this school year when Travis Stockhorst from Borgia reached out to Kemper about the repair.

“At the start of this year, Travis asked if we could get it done, and I said sure,” Kemper said. “The step was made out of tread plate, which gives it a textured, slip-resistant surface. We keep that material on hand, so I showed the students how to measure the old rusted step for all dimensions.”

What made the project even more unique was the use of FRCC’s CNC Press Brake, a rare feature in high school-level tech programs.

“I don’t know of any other tech schools that have a CNC Press Brake in their shop. This allowed us to bend the material to perfectly match the original part,” Kemper explained.

With guidance from their instructors, the students sheared the metal to size, bent it using the press brake, assembled the pieces, and welded them into a finished product. They then applied three coats of paint before Stockhorst brought the bus back for the final installation.

“These boys blocked the wheels, hoisted the truck up, and within an hour had it installed,” Kemper said. “I was very impressed with their efficiency. I always tell them: if you take your time, measure twice, and cut once, you’ll end up with a professional job. They were super impressed with the finished product - and that’s exactly what we try to instill in them.”

The project not only served as a powerful learning experience for the welding students, but also demonstrated the real-world value of career and technical education at Four Rivers Career Center.

Pictures from the FRCC welding project are below.