New State, New Shop

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Blog series by DrPuk2U updated 01-10-2013 06:06 PM 12 parts 42713 reads 37 comments total

Part 1: First Steps

03-26-2012 08:12 PM by DrPuk2U | 3 comments »

This is my first foray into blogging about my workshop. Whether or not I keep up the blog is questionable, but I thought it might be interesting (to me at least). A little bit of history to start with. I did a bit of woodworking as a kid (lo these many years), partly at school in woodshop class, more at home. Problem was that my father had two left hands when it came to tools and my sole power tool was a 1/4” power drill. But I managed to build a pretty cool workbench with vise, ...

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Part 2: Step 2 and 3 - the saw and the jointer...

04-08-2012 09:04 PM by DrPuk2U | 3 comments »

We moved to our new home in northern Illinois more than a year ago and I spent a lot of time planning the shop, drawing plan after plan, searching the net for ideas and so on.To give her credit, my wife tired of the plans (even though I told her it was half the fun) and gave me a SawStop Professional Cabinet Saw for Christmas! If you wonder why I went hog-wild with a SawStop, I’ll tell you that one of my long-standing rules, even back in my days up north was “nobody gets injured, ...

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Part 3: First Project - Rolling Outfeed Cart

04-15-2012 02:24 PM by DrPuk2U | 1 comment »

So now I had the saw and the jointer set up. I went to a local lumberyard (Woodstock Lumber) and bought 14 16-foot 2×12s and 3 sheets of baltic birch plywood. The 2×12s I stickered and left in the middle of the garage. The plywood was for building three rolling carts, patterned after the ones in Fine Woodworking #190. My intent was to build one cart the exact same height as my saw and use it as an outfeed table. Then build another to hold the planer such that the outfeed for ...

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Part 4: Rippin' and Grippin'

04-16-2012 09:10 AM by DrPuk2U | 3 comments »

Well, the wall hasn’t gone up yet – the start got postponed a day or so. And I had time to start ripping down the yellow pine 2×12s This proved interesting, so I thought I would post a short snippet about that. I ran into a frustrating problem so I will probably post this on the forum as well. My plan is to build a big heavy Holtzapffel bench a la Chris Schwartz et al. Supposedly, yellow pine is a good candidate, strong, heavy and relatively cheap. I’ve never us...

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Part 5: The Wall Goes Up!

04-30-2012 04:17 PM by DrPuk2U | 7 comments »

So, for a number of reasons, I decided to split our 4-car garage into two halves by putting a wall down the center. This has a number of advantages: Sound insulation from the rest of the house I can keep the shop air-conditioned without try to cool the whole garage Gives me more space to hang stuff, including lumber More electrical in the wall to make the shop more flexible The downside, aside from the cost (which wasn’t bad) was that it makes the remaining side a bit d...

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Part 6: Bench Assemblies and Flattening the Top

07-13-2012 01:13 AM by DrPuk2U | 1 comment »

Like many other people putting together a shop and trying to work with wood, I wanted a good bench. I have a nice “machine” bench made of 3 laminated layers of 3/4” birch plywood 8’ long on two tiers of metal drawers with a nice 6” machinist vise, but I needed to build a woodworking bench, as it would be useful and building it would be an excellent experience (how little I knew!) So after reading innumerable articles, I decided I would build the Holtzapffel b...

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Part 7: Brush Your Teeth!

07-13-2012 01:27 AM by DrPuk2U | 2 comments »

Been quiet for a while. Quite busy with traveling and some other non-wood activities. But I haven’t been idle. Made some progress on shop tasks as well as some honey-dos outside the shop. Continued working on my Holtzapffel bench – learning a lot about how to use the tools I’ve got. I have completed the top, legs and stretchers – or least roughly. A little flattening and trimming to do, but I am thinking of that as part of assembling the frame. I’ll get to that as soon...

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Part 8: A Tale told by an Idiot

08-15-2012 05:48 PM by DrPuk2U | 6 comments »

It was certainly full of sound and fury for about 15 minutes, but perhaps it signifies something – like me learning yet another lesson… :-) I spent most of the summer since July 4th away from home – in sunny San Jose, California. No, not a vacation, but working away on software, as usual. (Not that I didn’t enjoy the weather which was its usual monotonous perfection, but I hate living in a hotel). I finally am back home and taking a few days off. I swore I would get out in...

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Part 9: On Yer Feet!

08-31-2012 07:22 PM by DrPuk2U | 2 comments »

Well, it’s been a long haul, but I can (sort of) see the light at the end of the tunnel for my workbench. After the near-fiasco with the assembly of the frame, I turned to the humongous leg mortises. First step was to hoist the assembled legs and stretchers up onto the inverted top to mark the mortises. This was not too difficult even though the assembly must weigh 80-90 pounds. A little grunting and angling saved my back and got it up there. Positioned it carefully, clamped it d...

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Part 10: Clamp Rack

11-02-2012 06:24 PM by DrPuk2U | 3 comments »

I haven’t been blogging much lately – too busy. But I have made progress on the shop as you will see if you read this and the next blog I got tired of tripping over my clamps and having them all over the shop. I saw a couple of clamp racks on the web that looked good. Initially, I was going to go with one that was very simple but used a fair amount of wall space. Then I saw one that Stumpy Nubs created. I thought the general idea was good, so I copied his. Actually, I bou...

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Part 11: Holtzapfffel End Game

11-02-2012 07:11 PM by DrPuk2U | 2 comments »

Well, it took 6 months from the time I first bought the yellow pine, but I am glad to say that the bench is finally done. I could write a bunch about all the mistakes I made, stuff I learned, etc., but I won’t bore you with all that. Just a few quick comments. True to form, I made some silly mistakes, like relying on the dimensions in the Chris Schwarz article and forgetting that his legs were narrower than mine so this nicely cut inset for the end-vise was in the wrong place. N...

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Part 12: Up-grading the Dust Collection

01-10-2013 06:06 PM by DrPuk2U | 4 comments »

When I first set up my shop, I bought a Delta 50-760 DC. It works well enough, but when jointing and planing a lot of wood the plastic bag fills up fairly rapidly and it is a PAIN to take off, empty and then re-install. Once you get the hang of it, the process is easier but it’s never easy and it almost inevitably ends up with a bunch of saw dust all over. So I decide to invest in a Oneida Super Dust Deputy. By the time I got it, I had realized that the fact that the Delta was mob...

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