A Behind-The-Scenes Look at Custom Ski Manufacturing with Mike McCabe

Manufacturing Happy Hour · 27 Dec 2022 · 51m

What this episode covers

Mike McCabe, CEO and co-founder of Folsom Custom Skis, explains how his company survives in a challenging industry by maintaining a lean, debt-free structure and focusing on deep customer consultation to tailor ski geometry and materials. He details the specific material science behind their skis, including the use of wood cores (aspen, poplar, maple, bamboo), composites (carbon fiber, fiberglass), and plastics, contrasting their robust US-based manufacturing with overseas mass production. McCabe shares advice for aspiring manufacturers, emphasizing the critical importance of financial literacy, personal resilience during early recession-era struggles, and hiring a passionate, small team to maintain quality control without external funding.

Other shows on the same ground, closest first.

  • Making It · 1h 06m

    361: It’s complicated

    Jimmy Diresta, Bob Clagett, and David Picciuto discuss their recent personal projects and industry observations. Jimmy details a failed attempt to cool his attic using ridge vents and the resulting HVAC issues, while Bob recounts the success of his 'Jimmy Speedway' go-kart event and the sudden death of his Festool miter saw. David shares his vacation experiences and the high cost of materials like Baltic birch plywood, while the group discusses Japanese tools like Otoro clamps and Toyo Steel toolboxes.

  • Product Startup · 49m

    044: Turning customizable jackets into a multi-million dollar business, Elyse Daniels of Exodus Wear

    Elyse Daniels, founder of Exodus Wear, explains how she turned a niche idea for fully customizable senior jackets into a multi-million dollar business by rejecting online customization tools in favor of hand-drawn student designs. She details her bootstrapped journey from a $6,000 investment to scaling production, emphasizing the critical importance of maintaining a diverse network of manufacturers in China to mitigate risk and negotiate better terms. Daniels also shares her sales strategy, which relies on aggressive cold calling and a premium pricing model that avoids discounting to preserve brand value and customer loyalty.

  • How I Built This · 1h 01m

    Room & Board: John Gabbert. A Broken Deal, a Family Rift, and the Birth of a Furniture Giant

    John Gabbert, founder of Room & Board, explains how a 1972 trip to IKEA inspired him to create a modern, American-made furniture brand after his father reneged on a deal to sell him the family business, Gabberts. Gabbert details his strategic pivot from flat-pack particle board to high-quality, steel-framed solid wood furniture, leveraging small New England manufacturers to compete with imports. He emphasizes his refusal of private equity and outside investors, choosing instead to grow organically and eventually transition the company to employee ownership via an ESOP.

  • Shop Talk Live · 1h 14m

    STL 93: Nick Offerman's Dream Shop

    Actor and woodworker Nick Offerman discusses his Los Angeles-based Offerman Woodshop, a self-supporting co-op model where independent woodworkers contribute to overhead while selling their own commissions and products. He details his approach to working with large, green slabs of red oak and walnut, his admiration for George Nakashima, and the challenges of sourcing materials in a market dominated by high-end investors. The episode also features Fine Woodworking editors Ed Fernick, Mike Pekovich, and Matt Kenny answering listener questions on flattening cupped slabs, cutting through-wedged tenons, and selecting wood species for mid-century modern furniture.

  • Product Startup · 49m

    005: Miniature Construction Materials

    Mat Hofma and Erik Polumbo, founders of Mini Materials, explain how they launched a business selling miniature cinder blocks and pallets using a budget of under $500 for prototyping. They detail their process of 3D printing, creating silicone molds, and casting real concrete, while leveraging Instagram and Reddit for organic marketing. The duo discusses their decision to keep manufacturing in the U.S. to maintain margins and quality, and their strategy for scaling production by contracting local individuals rather than using large overseas factories.

The summary, chapters and topics are generated from the episode’s audio by this directory, not written by Manufacturing Happy Hour. The episode itself belongs to its publisher.