A very good set of instructional videos has been produced by MIT. It is intended for students who use their model shop rather than for people in training as machinists. It is quite good, emphasizes safety and shows the right way to use grinders, sanders. band saws, drill presses, mills, and lathes.
http://techtv.mit.edu/videos/142-machine-shop-1 Shop intro, Layout techniques, Drill Press, Hole tapping
http://techtv.mit.edu/videos/130-machine-shop-2 Drilling holes, Drill Bits, Bandsaw
http://techtv.mit.edu/videos/181-machine-shop-3 Belt sander, Small belt sander, bench grinder, Deburring and buffing, Finishing techniques, Shop safety and techniques
http://techtv.mit.edu/videos/127-machine-shop-4 Milling machine Basic operation
http://techtv.mit.edu/videos/84-machine-shop-5 Mill Collet block sets, V blocks, Hold down clamps, Angle blocks, Drill press vise, Lathe chuck with vise, Double Sided Tape, Squaring high aspect ratio parts, Right angle attachment, Slitting saw, Rotary table, Coaxial dial indicator, Collet indexer
http://techtv.mit.edu/videos/143-machine-shop-6 Mill Squaring a block, Squaring a plate, using edge finder, drilling holes
http://techtv.mit.edu/videos/183-machine-shop-7 Mill Reaming and Boring
http://techtv.mit.edu/videos/144-machine-shop-8 Lathe Basic operations
http://techtv.mit.edu/videos/134-machine-shop-9 Lathe 2 Tapping, Boring, Knurling, Tapers with compound, Turning shafts with live center, Single point thread turning
http://techtv.mit.edu/videos/172-machine-shop-10 Lathe 3
One of the mentors on 1648 has put together on-line tests for some of these. His students have to pass the tests before working with the tools. I'll see if he will make them available.
As far as insurance and liability go, there isn't much out there to protect mentors unless they are teachers working for a school system that provides some protection. Also, teachers may join professional organizations that provide legal assistance if needed; otherwise, mentors seem to be pretty much on their own. Talk to your own insurance agent to see what can be done through your home insurance, and talk to your school officials about coverage for students.
A level of insurance can be provided if your team through the Learning for Life program (
http://exploring.learningforlife.org/). This is done through a subsidiary of the Boy Scouts of America. It is a career exploration program which provides a good level of insurance for all involved. Essentially, you set up a BSA post for your team and school. You get access to training materials, career interest tests, and many other good things. Cost per student is quite low--only a few dollars, and you get all the benefits.
Dr. Bob