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#1 ·
Home Again (JOY!)

Back in Big Sky Country!

I have been home about three weeks now and I have been quite busy settling back in. I am so happy to be back with my wife, Rita, and my two dogs.

The geography here is so good to see again. Here is the view out my backyard towards the Yellowstone River.

Backyard View

The first thing I had to do was unpack and start settling back into my life at home and in my shop. I have been working for most of the last 4 1/2 years just north of Columbus, OH on some great projects. But I am determined to stay home now and ship or deliver any future projects.

Next I had to start making contacts all over town to let the people of Billings know that I am back and offering my services in my own home town. I have made more contacts than ever before. I know that there will be a delay before calls start coming in so I had to do this immediately.

I have been looking at a few remodel jobs and working on some bids, but I realized that I need to increase efficiency in my shop before I get too much going.

Finishing The Shop Walls

I ran some more circuits and started closing the walls up with sheetrock. I am very excited to see the shop getting brighter already. It will make it easier to heat with the walls properly closed up too.

Things are a bit cramped since I had to pull everything away from the wall to work. I will do this section and even paint it. Then I can move everything back and pull the stuff away from the wall and execute the next section. I will add more circuits and close the walls up with sheetrock and paint. I can't wait!

Finishing The Shop Walls

I really haven't had much time to get online and share with the great LJ brothers or to check out the projects and read the blogs.

I just realized that I have not even added my closet into the projects section yet. I blogged it so heavily but I need to add it to the brag board.

Gotta get back out and add another coat of mud. I am so happy to be back in my own shop!

Peace, Love, and Woodworking
 
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#169 ·
New Shop Lighting

Bright Light! Bright Light!

Over the last couple of days I added lights to brighten the shop.

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Shop Light Envy

After seeing the lights in Les Hasting's shop I was motivated to install more lights in my own. There is nothing like shop envy to motivate a guy.

The Original Lighting

The original lighting situation in my shop was poor and inadequate. I had three 4'x4' units with 6 bulbs over the assembly and finish area. There was only one of these 4'x4' lights over the tablesaw, planer, and sanding machine. This is the milling area.

In this picture it looks like there is ample lighting and there was - but only in the daytime. As you can see, I have large 5'w x 4'h windows that let in plenty of outside light and ventilation.

Old Arrangement of Shop Lights

The light was spread thin over the shop. The inadequate lighting left dark spots in the shop. There was always a shadow cast on the sides of a project and it was necessary to pull a project into a bright spot for critical viewing.

It all started by removing the diffuser panels from the 4'x4' lights. I was originally cleaning them but I was thinking how much brighter they were without the diffusers. At this point I removed all of them and decided that this would work better.

You may wonder why use the diffusers to begin with? The diffusers more evenly distribute the light, and with an inadequate number of lights on the ceiling, this is a bit more important but also a trade-off. You cast the light out further by the prisms of the diffuser panel, but it is also reduced. It almost seems to have a veil over the light.

Over time the panels also tend to turn yellow which further reduces the light. The first thing that struck me by removing the panels, was how much whiter the light appeared.

This Just Ain't Enough

I decided that this was still leaving me with a woefully inadequate lighting situation. I used to do maintenance on commercial buildings and had 6 strip lights in storage left over from this work. I decided it was time to divert from my projects and install the lights.

I started by removing the single 4' x 4' surface mount light from above the milling area.

Removing Light

Layout

Layout followed and this can be difficult when you are working alone. I use a paint pole to help me do layout because I can hold it over a long span against the ceiling and walls. I simply transfer my measurements to the pole and then transfer them to the ceiling.

Set Measurement On A Painting Pole

Layout Using The Painting Pole

The area was basically broken into thirds. I consider the work area to start at the shelving, not at the wall. That means I consider the shelving to be the wall or perimeter and the work area is inside of that.

Updating The Lights

The lights were new in the box but they were actually several years old. Being old light fixtures meant that they had the old magnetic starter ballasts. I had electronic ballasts for replacement on hand so I changed them out. The magnetic ballasts would have worked, especially because my shop is heated, but I prefer the quick-start of the electronic units.

The city has a collection point for things like the old magnetic ballast because they contain chemical compounds like PCB's. I will take them to that collection point for responsible disposal.

Ballasts Need To Be Replaced

The Lights Go Up

I installed backers in the ceiling between the trusses because the light were falling only on the sheetrock with no good backers.

After that I put the lights up and it was easy by myself. The 4'x4' units are not that easy when working alone.

I also did a quick calculation and determined that I would use a new breaker so I dropped in a new circuit for this bank of lights. These lights are also switched separately from the other units so I wired in a couple of 3 way switches. They worked properly on the first try.

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Rearranging the 4'x4' Lights

The 4'x4' lights needed to be completely repositioned to add in the fourth light. They would stay on the same center line but I would move the end units out about 1 1/2' on each end. Then I would divide the space between them, move the third light over and raise the fourth light into position.

These lights are very heavy and unwieldy when working alone. To make things manageable, simple, and safe I fabricated brackets with moving tracks to hold and slide the lights by myself. These brackets butt against the side of the light fixtures and screw to the ceiling trusses.

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These brackets allowed me to remove the screws in the light fixtures and allow it would drop about 1/4" onto the bracket. I was able to slide the light over into it's new position and then reattach it to the ceiling. After the light was securely in position I removed the brackets from the ceiling.

In this picture you will notice the parabola reflector lights under the stereo speakers. I needed to use these because I was having trouble seeing in the poor lighting. I joyfully packed them away as soon as the install was complete.

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Final Install

I was pretty excited to fire up all of the lights and see how they lit up the shop. I couldn't wait until it got dark to see the real difference.

WOW! I can't believe the difference, it is sooo bright in my shop now. It is now a wonderfully lighted shop and it is just in time for the longer hours of darkness that are starting to come upon us as fall and winter are rapidly approaching.

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I am kicking myself for not doing this sooner. I have been struggling with poor lighting all this time and to think that I had everything that I needed to do this in my storage or on the shelves. The total cost for this project was $11.00 because I needed to buy a few bulbs.

The Specs

The total power consumption of this lighting setup is 1224 watts.

The light bulbs are 4' long T12's. I use the low energy 34w bulbs instead of the 40w bulbs. T8 bulbs burn 32w. So really, if you are using T12's you can further save energy by installing the 34w bulbs instead 40w's. There is a slight loss of lumens rating when going to 34w bulbs but it is not bad.

Total wattage if using 40w bulbs would be 1440w. I am saving 216w over 36 bulbs.

I hope that you were able to glean ideas and information from my experience.

Providing Nutrition for Woodworkers
 
#199 ·
Reorganizing the Shop - Again!

First Snow!

Yesterday we woke up to the first snow of the season. We ended up officially receiving 4.6" but it has mostly melted off by this morning.

First Snow 5 Oct 2009 - 1

Rita's garden is looking pretty sad. You may be wondering, and the answer is "yes." That is a genuine outhouse but the pit has been filled and it is used as a small gardening tool shed. Putting new shakes on the roof is on my honey-do list.

First Snow 5 Oct 2009 - 2

On to the shop…

I started working yesterday and I got one of those stray thoughts going about how I needed to move a couple of things around. The next thing I know, I have set my work aside and have torn into moving things around for a better organized shop.

Moving the crap around

I decided to move the compressor to another location and when I took down the mounted hose reel I was left with a scarred wall. Yesterday I did the patch work and today I will paint. The steel shelving unit that holds the fasteners will sit in the spot left of the electrical panel. It makes more sense to keep the fasteners close to me where I use them.

Wall Repair

I got one end of the room organized, but now I need to figure out where to hang my clamps. Thoughts of organizing the clamps is actually what started it all. I never use the double doors out the end of the shop so I may remove them because I could use solid wall real estate more at this time.

It does not look like I have done much yet, but the shelving with finishes and stain is in place and organized. All the mobile tools are parked against the wall. I will paint the other wall and get the fasteners shelving in place today.

One End Organized

Peace, Love, & Woodworking
 
#200 ·
...and I thought it was getting cold here in California! Your shop looks great! ...well not the Todd shop we have seen in your past pictures and videos, it looks our shops! ; ) I'm with you though, when things are where they are handy and organized life seems to just be better and working seems easier…
 
#228 ·
Shop Reorganization - Day 2

Getting Closer To Done

I don't think that a person is ever done with organizing the shop but I am getting close to done for this round of organization and resetting the shop.

I finished my drywall repairs and painted the wall. I have 3 cans of old paint and all of them are marked "shop walls" but none of them match. My guess is that I did not have them labeled and at some point I opened them for identification, thought it looked like the shop wall color and marked it as such. Now I have a mismatched paint color on the wall and it is driving me crazy.

When working remodel projects, there are a couple of things that I do to keep the dust contained and at a minimum. I close off the room with plastic and I use dust collection when I sand.

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I also use a type of drywall mud that has been formulated to coagulate and fall straight to the floor when sanded. I never thought it would work but I have been impressed with the results of working with it. Here is a shot of the box so that you can try it if the need arises.

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Chasing the Electric

One thing I believe in is creating access for future work when it comes to plumbing and electric. One way to do this is to create an accessible chase where everything comes together in the electrical panel.

I have removable baltic birch panels that cover the electrical chase. I needed to trim the sides so I installed ash trim.

I really appreciated the accessibility recently, a couple of weeks ago I installed new lights in the shop and wired in another circuit for them.

I hope TopamaxSurvivor appreciates my tidy electrical panel;)

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Next On The Agenda

I plan on moving the compressor out of the room and installing a couple of hose reels that I have in storage but never installed. It will be good to get away from the noise of the compressor, it is a screamer.

I also will remove the double doors that are blocked by the tools on mobile bases. I will keep the window above it but I need to hang my larger set of clamps so I need more wall space.

I will leave you with photos of the current condition and then head out to the shop to tear out some doors. I have a lot of work to get done today.

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What Have You Done For Your Shop Lately?
 
#229 ·
I think code require NM cable to be stapled within 12 inches of a junction/electrical box if not in conduit. I saw a long stretch of cable there above the box! ;)

JK, your shop is definitely cleaner now. They don't stay that way long for some reason. :)
 
#247 ·
Reorganizing and the Domino Effect

It Just Won't Stop!

I tore out some double doors at the end of the shop that I never use, I need the wall space to hang my clamps.

I figure that since I started doing this little reorganization I might as well finish it. I usually bite things off a couple days at a time and then wish that I had finished or done more. There never seems to be a convenient time to interrupt my work schedule for improving shop conditions, but the payoff is always big when it comes to improved work flow and efficiency.

I completely removed the doors and framed in a wall, insulated, and sheetrocked.

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Here's a tip for working on your own house or shop: Before removing trim work, be sure to score along the edge with a utility knife to help release it from the wall.

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All the snow melted that we received Monday, but as I removed the doors another weather front moved in and it started to snow again.

When I am removing doors and windows. I often depth-set the circular saw to just cut through the frame which creates segments that are easy to pry out.

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After tear out, I created a simple framed wall insert and installed it.

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I didn't waste any time getting the outside sheeted to stop the loss of heat from the building. I quickly followed with insulation.

At this point it amazed me to think how little money I have spent on installing lights and making these great improvements because I have so much material on hand left over from jobs. Just clearing out these materials is helping to organize the shop because it takes up so much space.

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If you are working alone it is necessary to find methods to make handling material easier. When hanging sheetrock alone I use blocks of wood temporarily screwed to the framing. This creates a no struggle install of large sheets.

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By the end of the day I had most of the mud work done because I used a quick setting joint compound. Today I will add the final coat of mud, sand, and paint.

I did not add electric because I plan on covering the wall with storage. If I choose to add power it will probably be in the wall behind the drill press and mortiser. The access is quite easy in this wall because there is no insulation.

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The Dominos Continue Falling

Besides changing the door into a wall, I started moving things around in the storage room (this is a 12'x16' space that is supposed to be my finish room) to accommodate the air compressor. It will be great to get this out of my work space and isolate the noise.

My thought of taking just a couple days to work on the shop is starting to drag out but I accomplished quite a bit in making a better work space.

Today I plan on finishing the wall and complete installation of the air compressor, 2 hose reels, and reorganizing the storage room. I almost forgot, I also need to figure out how the system for hanging the clamps.

I've got a full day so I better get going.

What Have You Done For Your Shop Lately?
 
#248 ·
Can't beat extra wall space. When you get a chance you might want to consider extending an outlet over there for some additional tool hook-up space. Of course, if you use that area for storage it doesn't really matter.

I wish I had half as much space as you do. My small shop in the basement is cramped and it gets cold in the garage in winter.
 
#266 ·
Reorganizing the Shop Day 4

Coming Down The Home Stretch

Yesterday I finished the mud work where I removed the double doors. I also took the opportunity to patch the wall and ceiling where flying projectiles had left their impressions.

I mounted a couple of hose reels that I bought several years ago. I had bought three originally and I mounted one but put the other two on the shelf. The first one broke and I tossed it during this round of organization. Now I have two but that is quite adequate for my shop.

I used chunks of 2×10 material and attached them to the ceiling, making sure that I hit the trusses with all of the screws.

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Before I attached the 2×10 to the ceiling I had laid out the bolt pattern for the hose reel mount. Then I drilled holes and installed carriage bolts through the back side. Once the 2×10 was mounted on the ceiling, the bolts were already in place to accept the base of the hose reel.

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I installed one hose reel over the extension on the table saw and one by the main work and assembly area. I have been working in the shop long enough to know my habits and work zones pretty well.

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I guess there is a benefit to not getting these things done earlier as I had intended. My shop layout has changed three times. This time I did not really change the layout, I just focused on better storage and organization using the same work zones.

I set the compressor in the storage room and the air supply lines are run in the attic. I can tell you that the real joy of woodworking comes from having the compressor in another room. My compressor has an oil free pump and it just howls when it is running. I can't believe that I did not do this sooner.

At the end of the night I applied the final coat of paint and set the fans on it. Today I will be able to push all the mobile tools back into place. I am looking forward to reclaiming my work space with better organization.

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You will notice that I left the window in place. I love that window. I never used the doors below it, but that window faces east and I enjoy having the sun come through it in the morning and the extra light that it brings to the shop. It also provides a view of the sandstone cliffs that rise from the banks of the Yellowstone River which is not far behind us.

A Look Outside

Time to head out to the shop. I have tools to put away and a mess of extension cords to find a home for. I am thankful for my heated shop, I see the ground is covered with snow again this morning.

What Have You Done In Your Shop Lately?
 
#280 ·
Reorganizing the Shop - Finishing Up

Almost Done

I only have a few things left on the list for this round of shop organization.

I need to get the clamps hanging on the wall. At the moment they are just laying on the floor. Before this started they were standing, piled in a corner. It was difficult to access them or pull them out individually, but I cannot neglect them for one more day on the floor. This has been their temporary home while I finished the wall.

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I also need to hang the extension cords. I have a lot of these because of my remodeling work. I am running out of room on the shelves and the wall so I bought a ceiling mounted hanger and will place it above the ladder storage area.
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I should also get the TV mounted on the wall. You will notice that it sits on the shaper. When I use the shaper it gets moved to the bench and so it goes back and forth as necessary.

Some Much More To Do

There are a lot of other things that I will need to do but I cannot afford the time. This has taken longer than I thought and I have projects to get done. I still have been taking calls, doing bids, and working on the shop all at the same time, this is the life of self-employment.

I do not do well with trying to work my business during the day and then work on the shop or house at night and on weekends. I have to fit these projects in my schedule and give them full attention as I would any other job.

Out of Touch

One thing that did surprise me is how long it takes to organize and go through things in storage or stuff that has gathered in the corner over time.

Remodeling is always a good time to go through and cull out the unused and unwanted items. On a remodeling project it is the client's job to organize their items, move out for me, and move back in. It is just my job to do the construction from design to finish. I seemed to have lost track of how much time it takes to do the client's job.

Current Status

Here is a shot of the end wall where I tore out the door. I will be hanging the clamps below the window.

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The materials stacked in this corner have been organized. The sheetgoods are stacked in the corner and the stock material belongs to pending projects.

Once the projects are done then I will shelve or burn anything left over. One way or another, nothing goes to waste.
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I will need to take another couple of days and pull everything off the unfinished wall, finish the electrical, and sheet it. I know that I will need to use plywood on this wall, placing sheetrock on this wall would be disastrous because it takes a beating.

There are other things on the shop improvement list but they will have to wait. When I work on the shop I have to work on the house. It is hard to justify to the wife why I am putting more time and money in the shop compared to the house.

Remember this: When Momma's happy - Everybody's Happy. If your wife sees what you can do to the house when you have a proper shop set-up, you will have her blessing to work on the shop.

Well, time to get back in the shop.

What Have You Done For Your Wife Lately?
 
#291 ·
Reorganizing the Shop - Complete (this round)

Grandkids And The Studio Furniture Movement

The space-time continuum changes when you add the grandkids factor to the intended work progress equation, but that is OK. Rita and I had a couple of the grandsons for the weekend and they spent some time in the shop with me.

I went out to the shop Saturday morning with the 2 boys in tow (ages 3 and 4) and thought that I would finish my organizational efforts in just a few hours - silly me. It took me all morning just to install the ceiling mounted hanger and sort the extension cords.

This turned out to be a great place to store the cords. I did not hang it from the truss because it was not in the right location. I put cross bracing in the attic and hung it exactly where needed.

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After installing the hanger and storing the extension cords I decided it was futile to juggle shop work and my duties as a grandpa. So I devoted the rest of my afternoon to the kids and helping them explore their woodworking skills.

I have an idea they may set up tent in the studio furniture camp based on these abstract pieces that they constructed. You could just see the gears turning in their head as they contemplated the construction of their projects. Notice the hard hat that one of them wore for safety.

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Clamp Storage

Sunday was quite productive. Rita did some things with the kids and so that freed me up to get the reorganization done.

Figuring out a system to hang various styles of clamps can be a tough one. The various styles and brands of clamps all require a different method for storage. I knew that I wanted to protect my new wall so I started by screwing five 2×6 studs horizontally to the wall.

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This turned out to be a good decision. The clamp collection may change over time and the method of hanging them may change but it can all be done on this foundation of 2×6's.

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The 2×6's are attached with heavy screws to bear the weight of the clamps which is quite substantial. The dimensional lumber not only provides a structural base for clamp storage, but also provides much needed stand-off from the wall.

I really like the clamps that Rockler sells. They sell a pipe clamp kit and and aluminum clamp that have feet which stand the clamp off of the table. This provides clearance for the handle to turn and also provides for a convenient method of hanging the clamps.

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I also used 2×6 material as a baseboard trim. This will provide the wall with solid protection from the mobile bases. I screwed the material to the wall for easy replacement in the future. The 2×6 seems to be the perfect height to provide optimum protection from the mobile equipment.

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A Bit of Help

I did not do all of the work by myself. When Rita returned with the grandkids, the oldest one came out to the shop to lend a hand with the organization effort.

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A Final Look

I did not get the TV mounted on the wall and there is a list of 50 other things that I could do to create better organization and storage but I need to get back to work. This project did not cost very much because I had quite a bit of the material on hand but it cost me a week's worth of my time. This effort should pay back big dividends in greater efficiency and smoother workflow.

The clamps were originally piled in the corner and a set of doors that were never used now is a solid wall providing much needed storage.

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Everybody's shop setup and needs are different, but I hope that sharing this organization effort helps give you some ideas for your shop.

Get out in the shop and DO something.
 
#321 ·
Sheet Goods Organizer

Increased Efficiency Through Better Organization

My shop environment is always shifting and evolving. The goal is to create an efficient space to work in.

My shop is not large by business or commercial standards and many hobbyists enjoy a work space as large as mine. But large shop or small, as a business I have to focus on efficiency to make money.

A Couple of Problems

One of the biggest offenders for this disorderly disaster was storage for sheet goods.

The goal is not to become a warehouse for materials but there will always be a certain amount of material left over from jobs. I have to admit it is nice having scrap material to create a template or throw together a small project without making a purchase.

Another problem is the pile of material that I consider active. It is that leaning pile of stock that I am working from for current projects. I notice that over time many of the pieces are no longer in active status but become stagnant and they should be put on the shelf or culled out.

My most recent effort addressed the storage problem for sheet goods. This was also next to the last wall that stood as bare studs and insulation so that needed to be addressed as well.

Here are a couple shots of my corner of shame. The clamps on the floor are already in their new home from a previous improvement project seen here.

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Maximizing Efficient Use of Available Space

The problem with this storage area is that there is a lot of unused space vertically. I decided that an organizer system would be a good way to contain the usable left over sheet stock.

First I installed 1/2" plywood on the wall. This wall gets a lot of material and equipment like ladders stacked against it so I did not want to use sheetrock because it will be abused.

I was left with a space between the wall and lumber storage rack that was 45" wide. My ceiling is a little over 10' high (10' studs with bottom plate and double top plate.)

I divided the space into thirds left to right and this gives 15" for each section. The outside wall is left for full sheets and long stock. The organizer is placed to the left.

The organizer is 32" deep on the inside. The top two sections are for pieces up to 50" and 62" tall. The smaller cubbies on the bottom are of various sizes at 44", 32", 27" (approx.) If material sticks out some that is OK. I determined the best dimensions to minimize waste and material purchase.

I find that the 50" and 62" cubbies are good for storing my shop help.

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Placing the small cubbies on the bottom works out well because I can easily place large left over pieces in the top cubbies without a ladder and the smallest pieces are easy to deal with on the bottom. I have seen storage with the smallest cubbies on top and it requires a step ladder to store or retrieve the pieces.

Now my left overs are well organized and the walls covered in plywood. (I did not bury my grandson in the cubby with material.)

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Everybody's storage needs and situation are different, but I hope this helps give some ideas.

Back to the shop, I am going to clean up that leaning "active" pile of stock. I wonder if I can get my helper out of preschool?

Share the Love~Share the Knowledge
 
#344 ·
Clearing the Lumber Shelves

On a Roll

After organizing the sheet goods I moved on to the lumber rack.

I did not get as much done as I would have liked because I had to go look at a job and I ended up making a couple of models for beam wraps and a light trough.

I got the three small shelves that hold stock up to 48" cleared off. I only kept the stickers for lumber and some blocks that hold projects off the table for finishing.

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I discovered the T-tracks that I intended to install on my bench and chopsaw station. Now I have yet another project to take care of.

Most of the wood has been cut up to burn. I kept some stock and bundled it for a local LumberJock. He got a Porter Cable dovetail jig for Christmas and there is enough stock to keep him busy making boxes for a while. The beam is not included in the giveaway, only the small shrink wrapped stock.

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Too bad there aren't more LumberJocks in town. I am sure that it won't take long for the shelves to start collecting lumber drops again.

Peace, Love, & Woodworking
 
#365 ·
Shop Organization Continues

Purging the Lumber Rack

Woodworkers naturally have the hoarding instinct and this must be kept in check with strict discipline. The lumber rack has been gathering leftover material and unique pieces of wood for years with little culling to insure the quality of the collection.

I cleared three small shelves first and gave a good stack of wood away to a local LumberJock member. He got a Porter Cable dovetail jig for Christmas and this will keep him busy with making boxes. I had the wood bundled and ready to go for a quick pickup, but while he was loading it up I was unloading more shelves saying, "Get it out of here!"

The dust that has collected over the years is extremely fine. I have been using the shop vac on each board as I pull it out to collect the dust before it gets disturbed. This is horrible stuff to breathe in and I probably should have just worn a mask, but this method did not generate any dust nor did it elicit nary a cough.

Clean as you go...

I was really getting into the cleaning action.

Getting into my work.

A Trip Down Memory Lane

It is amazing how many pieces of wood evoked clear memories of projects past. Some had a specific angle cut, measurement, or drawing on them and I could recall what I was thinking and doing the moment I made the those marks or that cut.

I also found some treasures that had been forgotten. Like the stash of white oak that my brother had shared with me. Some of it has spalted figure. There is not enough even spalting for a large project but perhaps a small Krenov influenced cabinet.

White Oak

Spalted White Oak

I have some reclaimed doug fir that had a previous life as a cross arm on an electric pole.

Reclaimed Doug

I took consideration of the zebra wood that I picked up in Ohio. I got a smokin' deal compared to what I pay here in Billings. As I recall it was only $8bf compared to the local price of $18bf at the time.

After taking an inventory of the lumber I started putting the keepers back on the shelves. The goal is to not have anything on the floor except material for projects that I am currently working on - not 4 months ago.

Loading Lumber Rack

Another goal is to use more discipline in what I allow myself to store. I have a difficult time letting wood go because I know the potential uses for each piece, but as a business, material is constantly flowing through the shop. I have come to realize that for the most part, most of it is fairly unremarkable and can be purchased when needed. It costs me money to allow overflowing material to slow down my operation.

Nothing is going to waste here, it can either be passed on to another woodworker for their enjoyment, or we can file it in the wood stove to collect the heat value from it.

Share the Love~Share the Excess Wood
 
#366 ·
Todd, your shop is really beginning to shape up. And I can tell from the second picture that you are really buying into the clean-up. You certainly an inspiration to the rest of us and I can assure you that my wife would be proud of your efforts. She often reminds me of a need to do something similar. :)

This is going to pay benefits from adding needed storage to your shop since we never seem to have enough and it will also simply improve the overall appearance of your shop. As a hobbyist appearance is not that important for me but, in your case, your shop area is one of the first things a client will notice when they walk through the door. Keeping a clean well ordered shop advertises that the same concepts will be translated into work that is going to be done for them.

Nice job. And it would go faster if you could just stay off the phone! :)
 
#386 ·
Lumber Storage Under Control

I Am On Fire!

It was -15° outside but I was burning up in the shop with an intense desire to organize the lumber rack and get rid of extra stock.

This was the last of three projects that I started during the Christmas/New Years week.
1. Sheet the last unfinished wall with plywood.
2. Create a sheet goods organizer
3. Organize lumber rack and get rid of extra lumber

Here is the before picture of the lumber storage area.

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But take a look at the lumber and sheet goods area now!

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I gave a lot of wood away to a local LJ member and I cut a lot of it to burn. We heat the house with a wood stove.

Storing too much material costs me money in lost time and wasted space. I needed to increase efficiency in the shop, and so organizing the lumber and sheet goods storage was compulsory to accomplish this.

Tomorrow I am milling a stack of timbers and I need the space. Take a look at the material for the project and you will see why I need to be disciplined with my space.

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The improvements I have done lately have cost me more in time than money. I encourage everyone to knock out some of those projects in the shop to create a safer and more efficient work environment.

This is a business for me so an efficient shop space is necessary. But even if you are a hobbyist, your time in the shop is valuable because you are limited by work and family obligations.

By organizing the shop you will be able to make the most of your time that you do get.

What Have You Done In Your Shop Lately?
 
#420 ·
A Little OCD Goes A Long Way

I Think I'm Sick…

I can't seem to stop organizing the shop.

I thought that I was done organizing and I started to move on with my project but did not get very far. I got sidetracked with getting my taxes together.

This led to the realization that I could dispose of 5 years worth of files and paperwork. This led to me emptying out several file storage containers and almost burning up my shredder.

I got a bug and started cleaning up the storage room. This allowed me to make more room for stuff from the shop that does not get used often, which means more room in the shop.

I had been using a tall box to contain items that were difficult to store. This consisted mostly of long items like painting poles, story sticks, copper pipe, and FastCap wall poles.

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Since getting this end of the shop organized, I had regretted not taking care of this last item. Now was the time to scratch that itch.

I cut the box down at least 30% of it's original size and found a home for it in the storage room. I got rid of some items that I was not using and had been storing for years. I found that everything fit nicely in the newly downsized box and now it no longer consumes space in my shop.

The door and the window above it was not trimmed yet and so I finished it off. To add the final touch, I found a new home for the push brooms and hung them up for easy access.

Here is the latest of how my newly reorganized shop looks. I need to stop obsessing over the details of organization now and REALLY get back to work.

(The wood stacked against the wall is part of the current project.)

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Peace, Love, & Obsession With Shop Organization
 
#445 ·
Shop Organization - The Payoff

Like Searching for El Dorado...

Open space in the wood shop can be as elusive as El Dorado, the lost city of gold. I am fortunate enough to have a shop large enough that I can have some open space to assemble and stage projects before sending them out.

Just as efficiency is critical for my survival, so is open space. Space is necessary to stage incoming materials, assemble, finish, and stage projects for shipping.

Space Is A Vacuum

Open space in the shop creates a vacuum and it will suck everything into itself. Fortunately in the shop, this is a matter of principal and not physics. Strict discipline in maintaining our workspace can keep control of this situation.

For me, it is critical for survival as a business to understand what costs me money in the shop and how to best utilize the space to make money. I have come to realize that I do NOT have space for storing. I am not in the warehouse/storage business and I cannot afford to store projects or materials. The material has to come in, get processed, and the project has to go out.

I have to make a choice to keep only select materials on hand and to allow my suppliers do what they do best. My local suppliers are in the business of maintaining, storing, and supplying the materials for me. I am fortunate that my two main suppliers are only 3 and 6 miles from my shop and I can rely on the convenience of this situation.

But even when I was working in Ohio, the same principles applied and my main suppliers were 28 and 40 miles (one way) from the shop. Making a good materials list and wisely picking the material yourself will minimize overages.

The Realization

The accumulation occurs over time. A little material left over from a job here then another job there… It is not something that happens all at once. And we are correct, the pieces can be used in another project, but we have to determine what are the odds that a particular piece of scrap will be used? For the type of projects and work that I do, I tend to use a certain size of wood or sheet goods. If it is smaller than that the odds are not good that it will be used for a long time if ever.

Most all woodworkers have a certain amount of space to store the materials. It may only be a corner of the room, the wall space over the workbench, or it may be a sizable lumber rack that fills a wall or two.

I have come to realize that I need to understand and strictly adhere to my storage limit. My limit is this; if it does not fit on the lumber rack or sheet goods organizer then something has to go. At this point I can call a local woodworker to give the material to or I can burn it. But I cannot afford to store it.

Pro Vs. Hobbyist

My reasoning and point of view is that of a business. As a hobbyist the reasons are different but the end result is the same (or should be.)

An unorganized and messy shop space is often sharing garage or living space. There is a simple principle that I share with my clients, "When Momma's happy - everybody's happy." If your spouse sees an unorganized and unused space, they will not be as supportive of your hobby. Maybe your space is unorganized but used, still it is an eyesore and the basic principal applies.

Hobby woodworkers have to split their time between work, family, and shop. If you are not operating as a business in the shop, understand that your time is just as valuable as mine. If it is difficult to function due to disorganization then you are wasting valuable time.

It is more difficult to get motivated to work in an unorganized shop. This leads to a shop that sees little use and in your spouse's mind a waste of money and space.

Safety

It can be stated without any debate that an unorganized shop is simply not as safe to work in as an organized shop. We participate in an inherently hazardous activity when we work in the shop. Keeping a clean and organized wood shop lends itself to a safer work environment.

Motivation Through Organization Envy

Organizing cost me more time than money. Some may have to shell out a few bucks to purchase or build organizing systems for tools and materials but the return on investment is huge.

Since my last organizational efforts I keep thinking to myself, "I can't believe I didn't do this sooner!" I hope this motivates others to get more organized so that they may be able to enjoy working in the shop as much as I do.

Many think that I have over 1,000 sf of shop space but I am functioning in 950 sf of shop space.

Ahhh, space…

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Share the Love~Share the Knowledge
 
#465 ·
Organization - Back At It Again!

Just when I thought I was done…

I started milling parts and realized that I needed my mobile parts cart. It is actually a 4' scaffold that I decided worked better as a mobile parts cart. Over the last couple of years it had turned into a permanent storage cart for templates and all around catch-all cart.

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I stopped work and got a few sticks of framing lumber. I picked the best I could find and cleaned them up in my sanding machine. I drilled 1/2" holes every six inches in two of them for inserting dowels to hang the templates on. I made a jig that held the stock at 15° to the forstner bit on the drill press. The angled dowels will hold the templates to the wall a little better.

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After drilling the holes, installing the 2×4's on the wall was easy. Then I drilled a 1" hole in each template to slide them over the dowels. The dowels were cut and inserted into the drilled holes of the 2×4's. Then I was able to hang all of the templates high up on the wall for storage.

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The templates are like trophies, they represent successful work that I have done. Once I make a template I hate to get rid of it. It seems that I have reused many of the templates again or used them as a starting point to make other templates that are similar but have some variation. This is especially true with arches.

When I emptied the cart, I maintained discipline and stored everything in the sheet goods organizer or the lumber rack. I even got rid of some pieces I was certain would never get used.

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Now I have a mobile parts organizer ready to use and a wall full of templates creating real "shop ambience."

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Share the Love~Share the Knowledge
 
#466 ·
Todd,
Now what are you going to do for a catch all. I am getting better the older I get, I have finally taught myself to stop wasting steps. If I'm going to the storage room at the rear of the shop I try to find something to take with me. If I repeat this everytime I walk across the shop, it sure makes it easy at the end of the day.
What I can't figure out is how to break my son of leaving waht ever is in his hand all over the place. I keep trying to get him to read your blog, but he keeps saying he doesn't have time.
I use those gray Rubbermaid carts for handling parts. I got used to them when I worked out in the field, and couldn't part with them whem I moved into the shop.
Right now I'm embareassed about the mess in my shop. I hate it that way, and find it hard to function. I'm still trying to recover from the move in November. I am no where near where I wanted to be by now with getting shop cabinets built. So not very many things are where I want them to be yet.
I have a big cyclone with this huge frame and stand so right now it is doing souble duty as a clamp rack. My joiner is 8' off the spot it calls home, due to jointing 22' long product. Band saw has the same problem to get enough room from the wall to resaw this long stock. It's all wood recovered out of a old barn built in the early 1800's. The customer wants to use it for flooring in her home up in Chicago.
http://s884.photobucket.com/albums/ac41/Taigert/Sad%20Lumber%20Jan%2019%202010/th_IM000528.jpg[/IMG][/URL[/URL]]

In this area you have to take the jobs that pay the bills, work has been real scarce around here. That is part of the reason the shop is in the shape it's in now. When money is tight the extra's like shop cabinets can wait a little while. I know the economy in this area has to get better in 2010, so I can get this place cleaned up.
I didn't mean to cry on your shoulder. When I see the way your shop has come along it makes me wish I was there to with my shop. Like they say rome wasn't built in a week.
This is how it looked eight weeks ago, all the green stuff is where there was carpet that was glued to the floor. A friend of mine had a tenant in here that was using it as a fitness center and when he evicted her she took it out for spite along with a lot of other things. So when we closed on the sale it was a suprise to us.

Oh well go have a cold drink you have earned it,
http://i884.photobucket.com/albums/ac41/Taigert/New%20Shop/022.jpg[/IMG[/URL]]
 
#490 ·
A New Site and Blog Start-Up

I have been a bit homeless and sharing off of other blogger's platforms.

I am starting my own site and blog that is directed to the woodworking community.

My current site is static and primarily functions as an online portfolio for my clients.

Well, I am actually rehashing what I posted at my new site.

You can check it out here:

http://www.americancraftsmanworkshop.com/
 
#502 ·
Mobile Parts Cart

During the construction of a project there is often a need for organizing and storing parts. This is obvously a temporary need because as the work progresses, you construct parts and then assemble them.

I like to use a 4' scaffold as a mobile cart to store and organize the parts that I have made.

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I bought my scaffold for $99 although I have noticed that the price has risen on them over the last couple of years. It comes with steel platform shelves to stand on and I used plywood to make more shelves. If it is not in use and I need more room, the shelves are removed so it can be folded and put in the storage room.

There are some nice storage carts on the market but I can still use this on a remodeling job as a scaffold. So it serves a dual purpose as it works well in the shop and in the field.

Share the Love~Share the Knowledge
 
#518 ·
Dust Collection

I often get questions about my dust collection set up and so I thought that I would share it with everyone. The dust collection in my shop is simple and may even be a bit of a disappointment to see. But the reality is that it works pretty well except for a few shortcomings.

Currently I am using a single stage, 2hp, 1500cfm rated dust collector wired for 220v. It is a 110/220v motor, but when wired to 110v it would dim the lights every time I fired it up so 220v is the best option.

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The dust collector came with a 30 micron cloth bag that worked OK for sawdust from the planer and tablesaw, but it just about killed me when I started using it on the sanding machine. The finest dust that comes off of the sanding machine would pass straight through the bags and go into my lungs. Using the original bag filter would result in three days of hacking up brown goo from my lungs, so I purchased a retro fit 1 micron pleated filter from Penn State Industries. These filters are well worth the money, they are amazing in comparison to the cloth bags.

You will notice that I have to use duct tape to seal the bottom bag onto the DC unit. This is one of the drawbacks if you purchase a dust collector and then a retro kit. The original setup was not intended to be used with the plastic bags and their particular needs for attachment. But this works OK, I just have to keep duct tape on hand. The retro kit did not come with a means of holding the bag and the metal band that was with the original cloth bag was a piece of junk.

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The dust collector is located closest to the sander because this is the most difficult machine to collect dust from. It has two ports and requires the most CFM. The 2hp motor provides enough suction but the biggest problem is that the dust collector is a single stage unit. For a sanding machine, a 2 stage DC unit is really necessary because it would help keep the filter clean for a longer period of time. I have plans to buy a cyclone but they are on hold at the moment. I know that I could use a garbage can with a cyclone lid and I may resort to this option.

The CFM requirements for a surface planer and tablesaw are not as great as the sanding machine. A tablesaw is difficult to collect from if you do not leave the dust collection shroud around the blade. I do not have the shroud mounted on mine so I get a certain amount of dust that comes off of the tablesaw. With this understanding, the dust collection from my tablesaw is quite satisfactory.

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The jointer has it's own dedicated dust collector. It is a small 3/4hp, 660cfm unit with the cloth bags. This works good because the jointer does not produce fine dust overall, it produces shavings.

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This small dust collector was actually my original. The bigger one came later but I kept the small one because using it worked out best for my shop layout and dust collection needs. I was glad that I kept it because a couple of times I hauled it to a remodeling jobsite. It's mobility has been a great asset to my business.

The dust collection system would benefit most with a smooth pipe run, but for the short distance I have to run a DC line, the corrugated hose works sufficiently without causing too much drop in the suction. I have a blast gate located at each tool and for my small system this works fine, I do not need to shut down whole runs to increase flow elsewhere.

Both of the dust collectors are activated by remote control units. I find that these are a great investment for the shop. I have the Woodcraft and ShopFox brands and they both work great. When you make the purchase, just be sure that the remote unit will handle the HP load of the dust collector.

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Dust Collection From Small Tools

I collect dust from my electric hand tools like the random orbital sander, belt sander, and biscuit joiner. But I will have to cover that setup with photos and a full write up at a later date;)

That is all for now.

Your friend in the shop - Todd A. Clippinger.

Share the Love~Share the Knowledge
 
#519 ·
Looks good, Todd. Have you tried to use weatherstripping around the bottom of your dust collector? I was getting some dust blowing out of the connection on my lower bag. I used 3/4" weather stripping between the clear bag and the metal strap. It formed an air tight seal and now I don't get any dust coming up from the lower bag.

Thanks for posting. i always enjoy reading your blogs.

Cory
 
#529 ·
Video Update

I have been anxious to get the cameras out and do some more video so I did an update from the American Craftsman Workshop.

Thanks to the following guys for helping me get my own site started. It is a work in progress at the moment, but they really helped me figure a lot of things out sooner than later.

Marc Spagnuolo - thewoodwhisperer.com

Matt Vanderlist - mattsbasementworkshop.com

Brian Havens - brianhavens.us

Troy Bouffard - birchhillwoodcrafts.com

Video review for Scott Morrison instructional DVD's

Savings of 15% offered by Scott Morrison at Finewoodworker.com. You will save on instructional videos, templates, and the new butterfly joint kit. This offer ends at the March 31st so be sure to get in on the savings.
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Scott's has a variety of videos and templates that will teach you how to build furniture inspired by Sam Maloof. He breaks the process down into comprehensive, easy to follow steps so that you can be successful building these pieces in your own shop.

Watch the video to see why the savings code is "Captain Clippinger."

Follow me on Twitter - Todd in Montana

Your friend in the shop-

Share the Love~Share the Discounts;)

 
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