In this conversation, Kevin Johnson interviews Charles McCarthy, a welding business owner who shares his journey from starting a small welding operation to managing a large fabrication company. Charles discusses the importance of keeping processes in-house to maintain quality and timelines, the challenges of scaling his business, and the strategies he employs for customer acquisition and hiring. He emphasizes the lessons learned from mistakes made along the way and his vision for future growth. In this conversation, Charles McCarthy shares his journey from a welding job to becoming a successful business owner. He discusses the challenges of scaling a business, the importance of building the right team, and the lessons learned from experience. He emphasizes the need for effective management, the significance of understanding customer needs, and the thrill of continuous improvement in business processes. The discussion also touches on common mistakes made by small business owners in the welding industry and highlights a unique success story involving hand sanitizer stands during the COVID-19 pandemic. In this conversation, Charles McCarthy shares his experiences of building a business during a crisis, navigating the challenges of selling on Amazon, and the importance of automation and technology in driving business growth. He emphasizes the need for data-driven decision-making and the impact of investing in the right tools and processes to enhance efficiency and profitability.

Chapters

00:00 Introduction and Overview of Charles' Business
03:01 Charles' Journey into Welding and Business Growth
07:20 Scaling the Business: From Garage to 21,000 Square Feet
10:38 Team Dynamics and In-House Processes
14:02 Customer Acquisition and Reputation Management
19:00 Challenges of In-House Operations and Learning Experiences
25:21 Hiring Practices and Employee Growth
32:00 Future Aspirations and Business Vision
41:13 From Welding to Business Owner
44:15 The Sprint to Business Independence
46:46 Navigating Growth Challenges
49:55 Building the Right Team
54:21 Key Roles for a Small Shop
01:01:24 Learning from Experience
01:04:47 Managing Expectations and Emotions
01:07:45 The Thrill of Business Ownership
01:12:26 Common Mistakes in the Welding Business
01:17:56 The Hand Sanitizer Stand Success
01:23:17 Building a Business During Crisis
01:28:01 Navigating Amazon's Marketplace Challenges
01:33:42 Automation and Estimation in Business
01:45:09 Investing in Technology for Growth
01:51:09 Data-Driven Decision Making

22-year-old Knox Carmichael left high school, got his GED, learned to weld, bought a $10K camper on Facebook Marketplace, and hit the road. He’s welded garbage trucks in Denver, aluminum Navy ships in Wisconsin, and now lives in his camper in Florida doing aerospace steel welding (UT/X-ray). He travels with his fiancée, plans to start Weld Fab Auto, and shares hard-won lessons on recruiters, test jitters, and why gatekeeping hurts the trade.

“Confidence is 90 % of welding.” – Knox

In this engaging episode, Nathan Leiter and Kevin Johnson dive into the challenges and triumphs of the welding community. Nathan shares his journey into the business side of welding, while Kevin discusses the exciting Fabricator Olympics and his goal to unite welders from all 50 states. Tune in for insights on starting your own venture and the importance of community support in the welding industry.

October 11th 2025

www.FabricatorOlympics.com