I spent most of a year getting the shop up and running including wiring, some light construction, building the shop furniture and storage, and tuning up tools before I really started making furniture. It was good practice and helped give me a better idea of how to approach the projects I was planning. For you denizens of rec.woodworking, I guess my philosophy on woodworking is kind of a half Norm, half Neander hybrid. I love handplaning, but can't beat the machines for getting the grunt work done.
Here's
the entry showing the 60A sub panel I wired in to feed the shop, the mandatory
Fleet Farm calendar, and the fire extinguisher (Class ABC dry chemical)
that no shop should be without. The sub panel has a separate 220V
circuit for the dust collector, and one for the big tools (TS, BS, jointer).
The lights are wired on 2 circuits, one from the sub panel and one home
run from the main panel so that it won't get dark suddenly The entry stairs
are just behind the post and railing and the stairs bend 45 degrees at
the left of the post. The railing segment to the left of the post
is screwed in place so that it can be removed for getting big stuff or
long boards down into the shop. My advice for those building a house
with a basement shop: Direct access to the outside, preferably walkout.
We bought this house already built (it was a model home) so I didn't have
the option.
Here
is a wide shot of the shop looking from the back (south) corner.
The dust collector is behind the camera and currently is rolled around
to reach wherever it is needed. I want to install duct work and a
cyclone, but have not got there yet. For a look at a serious
dust collection system, check out the Megasuck 2000 at my
woodworking buddy Brook's
web site. In this shot you can see the Unisaw (the cutoff sled is
on the saw here) with the melamine outfeed table just past it. I
borrowed the concept from a FWW article on a "small" shop in a 2-car garage
(I'd kill for a shop that small :-) where there is a 2-piece sliding
bridge of 3/4" melamine that rides on set of rails on the outfeed table
and the saw. This way I can get 4-sided access to the table for assembly
work, and have continuous outfeed support when I need it. It works
great. In the rear is the 4-tier cantilevered wood rack described
below in more detail. Just to the right of the wood rack you can
see the DeWalt planer (tables folded up) and the drill press to the
right of the planer (barely in the shot). The garbage can in the
lower left corner is just in front of the router table (see below).
To the right of the table saw (out of the shot) is the bandsaw (see below).
Several pipe clamps are leaning against the west-facing window sill, which
is the only window in the shop.
The
bandsaw is a restored early 30's vintage Delta 14" that I bought off a
guy who liked restoring old tools. It turned out to be substantially
older than I had thought (I guessed 50's or so) thanks to some info from
Keith Bohn. (Thanks!) He did a nice job and even threw in a homemade plywood
stand. I had to add the motor, switch, and riser block. The
motor is 1.5hp (1725rpm), so stalling is not an option. The
riser block installation was a real hoot as the 40-some-odd year old bolt
holding the upper and lower castings together wouldn't come apart for anything.
I used a 3' breaker bar... and broke the socket. I tried a hefty
1/2" Ingersoll-Rand air impact wrench and it wouldn't budge. I torched
it, and it still wouldn't budge. I finally had to cut the nut off
the bolt in tiny pieces using a cutoff wheel and air chisel. Thank
God for air tools...
The switch is another story, too. It is a magnetic safety switch,
like the type that come on most big power tools these days, except I built
it myself from scratch. I originally purchased one from the local
Woodcraft store, but was unhappy with the quality so I went out and
got industrial quality parts and built my own for less money.
The
router table is basically a cabinet with a bank of drawers on each side.
The chamber that the router is in has a simple pull-off door of 1/4" Lexan
attached with two magnetic catches. The plywood door below it is
similar. Dust collection is via PVC pipe components (the closet flange
is visible below the router) that go down into the lower chamber, out the
back and straight up where the hose is attached. Another smaller
hose is used as a pickup near the bit. I borrowed this concept from
a web page on the "Woodworker's Gazette", but I'm not sure if that site
is still alive. The switch is magnetic like the bandsaw, and again
homemade. I found out one interesting factoid: A magnetic switch
is incompatible with GFCI circuits (the GFCI trips), which the 110 outlets
were. I changed the one outlet for the router table back to regular
to fix it. The dust collection on this is not as good as I was hoping
for, as a lot of it collects in the chamber rather than finding it's way
out the port. At least I don't get a dust cloud when I use it.
The
lumber rack. 2x4's secured to the floor and bolted to the joists
above with 2x6 cantilevered arms sticking out 18". The arms are half
lapped, glued and screwed to the uprights. Cantilevered structures
aren't the sturdiest in general (can you tell I'm an engineer yet?) so
you want to make sure it is as solid as can be. I would prefer a
rack that was supported on both ends as you could stack it up to the ceiling
without fear, but I don't have space for that type of layout, so I made
do with this design. There is an 8" space behind the uprights where
I can store sheet goods on edge. I think I saw that idea in a ShopNotes
or something similar. The bottom two tiers are loaded down with a
bunch of Quarter sawn White Oak (mostly 4/4, but a few boards of 6/4 and
8/4 too). The oak is so dense and heavy that I didn't dare stack
it up higher, so the bulk of it is on the base level which sits directly
on the floor. The top two tiers have a little red oak and some leftover
maple from the workbench along with a small stack of 4/4 poplar for misc
shop use, drawer sides, and other secondary wood uses. All the wood
is rough sawn. I have another stack of not-so-great plain sawn white
oak in the garage that I got at a sawmill auction with a friend.
I really need to get some more wood varieties. I'd like a stack of
walnut and cherry next, but storage space could be tough.
The
workbench is a rather crude but effective design. The base is 2x4's,
2x6's, and plywood glued up into several sub-assemblies and bolted together
to allow disassembly. The top sets in place on 4 dowels for location
and to keep it from shifting. The top is not the solid maple slab
it may appear to be. It was based on a part of a design from a Shop
Notes workbench project and is the worst mistake I have made in the shop
(so far...). The top construction is a sub-base of 3 layers of plywood
laminated together with a 4/4 maple board slab glued to the top of it.
Every time I thought about it, I felt that this construction was a disaster
waiting to happen as it doesn't allow for proper wood movement, but hey,
if it worked for ShopNotes, all should be well, right? Bzzzzzt.
It
has since split in a big way. Lesson: Listen to that Little Voice.
Aside from that issue, it is very solid and has served me well. The face vise is a Record 52 1/2 (should have got the 53), and the full width tail vise is the Veritas Twin-Screw (on the far end of the bench). I recommend drilling bench dog holes every 6", as I started out with holes every foot, and quickly found myself drilling some more. The drawers are two separate banks that just slide in place. The top is about 30" deep x 72" long. The size isn't bad, but I find I do a lot of handplaning on it for truing up boards and only use the first 12" of depth a lot. I can see why a "Jointer's bench" is usually so narrow, but this bench still has more general uses than just hand planing so the extra width makes sense. Perhaps in my "next" shop I will make a jointer's bench just for handplaning. It would be nice to be able to reach the board from both sides of the bench while planing. The one final lesson I learned from making the bench is that handplanes + maple = tearout like you've never seen. Just too many changes in grain direction in maple.
Wanna see what's in the drawers?
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