Workshop Organization

Shop is about 24'x14'.

Inventory

Large tools

• Miter saw
• Band saw
• Table saw
• scroll saw
• lathe
• Drill press
• planar
• joiner
• router table
• belt sander
• Dust Collector

Power tools.

Build Plan

Prototype

1. [DONE] Drill press : Simple and small
2. [DONE] Work surface: Full size, allows me to start standardizing connections
3. [DONE] Electrical: I think I need to re-wire the work surface, the input should be on the right, match this on the drill press.
4. Bandsaw : Being able to move this would let me extend material storage behind this.
5. T-Track: Add two tracks to the work surface. I'm not going to match these to the table saw
6. Fix Dust collection: The pipe on the work surface bench can't connect to a neighbor. Choose a flange direction and make a fitting pipe.
7. Fastner: Connect the drill press and work surface both ways.
8. Swap Back Wheels on drill press and work surface 1
9. Miter Saw: Once this is done I can tear out the current workbench
10. Tear out workbench.
11. Table Saw: Table saw actually takes a lot of room and produces a lot of dust. That will be next.
12. Flip Top 1 : doing one of these will help get my footing.

Later

• Standardize drawers and start building them.

Lights

I have one overhead light, but it's not enough if I want to work after sunset. I want to get more of the aluminum reflectors and put LED bulbs in and place them through the garage. I can hook them up to the same circuit as the dust collector, there should be plenty of overhead there.

Modular Carts

The base cart is 2'x2'. Larger carts can be a multiple. The carts are connected with "barbells" - bolts with washers and wingnuts. The wheels are locking casters. I'm also going to wire up an outlet on each to allow for chaining power.

I should try to make the brake wheels leveling.

Brake levers need 4.75" clearance. On a 3.5" base that means 3" inset for a total of 6.5". On a cart the vertical supports can run the narrow way so their inside edge should be 5.5" from outside. On a 24" cart that means the inside gap should be 13". On a 48" cart, there's 37" internal. Divided into 3 sections, there'd be 2 additional 1.5" supports, which gives 34". So 11 1/3" would be ideal. Which means for the 2' cart, we inset a little more.

I need to make a template for the back with a hole for the dust collector and one for the outlet. I think that will be about 6".

Lift Cart

Inspired by this.

Need good casters. 8" rubber so it can handle the lip out of the garage. Another idea would be treads. That would accommodate smaller wheels

I think it will perform better if I use aluminum conduit or black pipe for the parts that need to rotate (3 on each arm). A wider shaft will result in less play and if it extends all the way across it will limit twist. Instead of wheels, steel on steel with graphite lubricant may work very well. Though I do have a handful of bearings, so maybe I should just use those.

The goal also isn't to lift high, 4" would be plenty. It will be easier to build a solid structure with a smaller range of movement.

The all-thread rod is very strong under tension, so it should be oriented to pull the load.

I could also make my own wheels. I've got bearings, I can buy an inner tube and a rubber wheel. Just make the body out of plywood. Not sure how much I actually save though.

Instead of casters I could do steering linkage on the front.

• 8" No bearing $9.20
• 6" Bearing $12.70
• 6" Bearing $13.30
• 8" Bearing $9.45 - Winner?

I can orient this for pull rather than push (like a wagon). I can connect the handle to the screw with a universal joint.

Modules

For the flip tables I should look for tools with similar work heights that will probably not be needed at the same time.

Modular Attributes

• Electrical
• French Cleats
• T-Track
• Dust collection
• Pneumatic
• Physical connector (probably bolts or "dumbbells")
• drawers (like Jers Shop)

Dust collection is tricky with the flip tools. I could make the flip axle a 4" pipe and run collection through that, thinner pipe could work for some tools. I could create a hollow cavity underneath (where the unused tool is) and route the dust into the cavity. I could also just use dedicated carts; I can line up 12 one deep along the wall and still have several off shoots or store a few in the corner.

The electrical plug (input) should be on the right. The outlet should be on the left.

I need to figure out connections for dust collection. I need a quick and easy way to to connect two and I need an easy way to plug the last one. I'll also eventually need to add bends and T's.

Work Top (2x4)

This module has a swappable work top. Tops all store underneath. To accommodate this, they need to be stored at an angle.

• Flat
• T-Track (make this standard to line up with miter saw and router table)
• out feed (rollers)

For one of the work surfaces, add a downdraft table.

Miter Saw (2x2)

Add wings that can lock up with T track or fold down out of the way. Should have a hood behind it for dust collection.

https://www.youtube.com/watch?v=quZyNrp8mq0

https://www.youtube.com/watch?v=jkizx58fhDc

The wings really provide a challenge because they need to be out of the way when down so it can mate to another cart, but also be strong and flush when up. I think the way to do this is rather than folding, have them slide into place with a sort of T track - some positive lock configuration and have two keys on the wings, one up and one down.

Ryobi Cabinet (2x4)

Space for all the ryobi tools. The power adapter will be stored here. I'd like an insulated area where I can store and charge batteries.

Router Table (2x2)

Router table, connect both routers. Storage for bits.

Bandsaw (2x2)

Obviously, needs to be built strong.

Belt Sander / Planer (2x2)

Flip top. Planer in/out feed should be at working height.

It may make more sense to have the belt sander with a sanding module. Could do a downdraft table.

Scroll Saw / Jointer (2x2)

Check, the Jointer may be the same size as the lathe, that would be a better pairing.

Drill Press

The drill press is easy, the trick to doing this well is good storage.

Table Saw

Not sure what size yet. I could almost do a 2x2, but I could also see 2x4 or 4x4. Lots of storage for jigs would be good.

I kind of think I should make up a few of the jigs I've been putting off, then figure out how much storage I need and build to that.

Box Kits

These are boxes of related tools that I want to setup

Sharpening

The sharpening stones, a strop, the angle jig.

Sand paper sheets

I've got these in the binder, and that sort of works. I'd like to make a hand sanding block

Wood Storage

I'd like to rebuild this because I'm not confident in the strength and it's not great for sheet goods.

Behind the rack I'd like about 12" for sheet goods (check inventory). Two racks each ~4.5'. The front will be simple shelves. I don't want the angular support, they take up too much space. Instead the horizontal supports will go back and be glued into a 2x4 along with a slight dado. I can also put the entire thing on casters, probably 6 or 8.

The whole thing should be no more than 3' deep, otherwise I'm not really getting any room back and I think 2.5' would be a great target.

I'd also like more shelves than I currently have because the wood is stacked too deep and I can't get to some of the stuff I have. I should also do some bins on the bottom so I can store sheet scrap. I'll disassemble the current sheet cart I have.

So I'm looking at roughly 2.5 x 8 x 10. The only issue with building this now is that I don't thing I have enough 10' board - check.