Author Topic: On-going shop reorganization build thread [updated 6.30.17]  (Read 21462 times)

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Offline ear3

  • Posts: 3289
Re: On-going shop reorganization build thread [updated 6.28.16]
« Reply #30 on: July 13, 2015, 10:37 PM »
Took my weekend away from the installation to do the workbench, using the Woodrave Template and a Bosch 20mm boring bit that I will never use again due to the burning.

I spent a long time thinking about what the perfect workbench might look like, but then I realized that the perfect workbench was simply one that fir my needs at the moment.  And I can always modify it as my needs change.

My three principles were these:

1. Have space underneath to fit my metal filing cabinets, with enough room from the top of the cabinet to tighten knobs underneath

2. Have space underneath to place the Festool CT

3. Match the length of the existing cabinet I built a few months ago

I'll use the bench largely for sanding and assembly rather than cutting.  I don't do much hand planing so I thought the 3/4 MDF would be good enough.

I put some dadoes in the 5/4 edging and put in Incra T-tracks, and will later add additional dados on top for a T-track along the edge so that I can get some of those auto lock T-track clamps like Rockler makes to supplement the Festool clamping elements when necessary, as well as additional hold down clamps.

Notched the three 4x4s with the Carvex for the 5/4 edging to nest in.  Put one cross piece underneath for additional support, and then secured it to a 2x4 running along the wall.  4x4s are also anchored into the concrete, so the bench is pretty solid.

Put a few coats of Danish oil on the MDF, and will finish it off with some wipe on poly.

Added a few dog holes down the 4x4s for support when I'm doing edge sanding on long boards.

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« Last Edit: July 13, 2015, 10:39 PM by Edward A Reno III »
Kapex KS 120 w/UG Cart and Extensions • CXS Set • T18+3 w/Centrotec Installer's Set • PDC 18/4 • TS 75 • TSC 55 • HKC 55 w/250, 420 and 670 FSK rails • Carvex 420 w/Accessory Kit • Domino 500 Set • Domino 700 XL • OF 2200 w/Base Accessory Kit • OF 1400 • OF 1010 • MFK 700 EQ Set • LR 32 • MFS 400 w/2000, 1000, and 700 extensions • Rotex 90 • Rotex 150 • LS 130 • ETS-EC 150/5 • ETS 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • DX 93 • RS 2 • HL 850 • Vecturo OS 400 • CT 26 w/Long-Life Bag • CT Sys w/Long-Life Bag • MFT/3

Offline ear3

  • Posts: 3289
Re: On-going shop reorganization build thread [updated 7.13.16]
« Reply #31 on: September 28, 2015, 05:04 PM »
One small space-saving addition.  I'm going to be building a miter saw cart for my Kapex, so I wanted to clear out some wall space for it to park it as close to the wall as possible.  So I took advantage of my low garage ceiling and moved some of the long clamp storage overhead.

Marked off a single piece of plywood with the slots, then ripped it down the middle once they were jigsawed to ensure a mirror image:

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BTW, I learned that my newly acquired Rockler bench cookies still work well after you accidentally jigsaw them!

I have overhead space now for up to 13 Bessey parallel and long bar clamps -- with the bar side tucked in above the open garage door:

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« Last Edit: September 28, 2015, 05:08 PM by Edward A Reno III »
Kapex KS 120 w/UG Cart and Extensions • CXS Set • T18+3 w/Centrotec Installer's Set • PDC 18/4 • TS 75 • TSC 55 • HKC 55 w/250, 420 and 670 FSK rails • Carvex 420 w/Accessory Kit • Domino 500 Set • Domino 700 XL • OF 2200 w/Base Accessory Kit • OF 1400 • OF 1010 • MFK 700 EQ Set • LR 32 • MFS 400 w/2000, 1000, and 700 extensions • Rotex 90 • Rotex 150 • LS 130 • ETS-EC 150/5 • ETS 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • DX 93 • RS 2 • HL 850 • Vecturo OS 400 • CT 26 w/Long-Life Bag • CT Sys w/Long-Life Bag • MFT/3

Offline Billy stray

  • Posts: 281
Re: On-going shop reorganization build thread [updated 9.28.16]
« Reply #32 on: September 28, 2015, 09:40 PM »
Good idea, I've worked out of small spaces b4 and there's nothing like that ah ha moment when you find just a little more room
« Last Edit: September 28, 2015, 09:49 PM by Billy stray »
Billy

Offline ear3

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Re: On-going shop reorganization build thread [updated 9.28.16]
« Reply #33 on: November 28, 2015, 09:38 AM »
I've been thinking about the design for the extension wing for my Kapex cart, but wanted to test out various sliding and folding solutions before I did something permanent, so I decided to experiment by building an folding outfeed table for my table saw.

I modified a design I found on the internetz so it could integrate with my Incra fence.  Basics of the table are two pieces of MDF or ply that get covered on both sides with laminate, and then edged out with solid wood (poplar in my case).

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The mounting "plate" was in two parts.  First was a piece of 5/4 poplar fitted with bolts and the sliding nuts that go in the track on the Incra fence extrusion.  It needed a rabbet at the top to give clearance for the fence to pass.  Screwed into this was another piece of 5/4 poplar, chiseled out to fit over the two central bolt heads of the first board.  This second board has the piano hinge at the bottom attaching it to the table panel.  In order to get the top flush, I predrilled the second piece to the first, and then removed it to hinge it to the panel.

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I bought a 48" hinge and cut down approximately 16" with the grinder, and then attached the panel:

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The leg mechanism is just a large sliding dovetail assembly made of plywood and poplar, attached with bolts to two radiused pieces fitted into dadoes I routed into the underside of the panel.  The leg slides until it fits into a wooden rest attached near the bottom of the table saw cabinet.  I cut up some metal shims with the grinder and attached them to the bottom of the sliding leg and the rest to firm up the assembly and avoid and changes in the level of the table due to wood degradation:

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After leveling out the top and marking the position, the leg got locked into place with two sliding bolts.

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Total surface area of the extension is 32x28, which gives me almost 5 feet of depth from the front of the saw to the drop off at the back of the extension.  I realize now that I could have even gotten away with less depth on the extension -- the Jessem stock guides I have on my fence act as a great hold down to keep pieces from tipping off too soon.  But the extension will definitely come in handy when I'm doing long rips of 8/4 material or other heavy stock.

I just realized I have put more money into accessories and modifications for the table saw then I originally spent on the saw itself.  It's been worth it, though, as I now have 100% confidence in the tool.
« Last Edit: November 28, 2015, 09:49 AM by Edward A Reno III »
Kapex KS 120 w/UG Cart and Extensions • CXS Set • T18+3 w/Centrotec Installer's Set • PDC 18/4 • TS 75 • TSC 55 • HKC 55 w/250, 420 and 670 FSK rails • Carvex 420 w/Accessory Kit • Domino 500 Set • Domino 700 XL • OF 2200 w/Base Accessory Kit • OF 1400 • OF 1010 • MFK 700 EQ Set • LR 32 • MFS 400 w/2000, 1000, and 700 extensions • Rotex 90 • Rotex 150 • LS 130 • ETS-EC 150/5 • ETS 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • DX 93 • RS 2 • HL 850 • Vecturo OS 400 • CT 26 w/Long-Life Bag • CT Sys w/Long-Life Bag • MFT/3

Offline ear3

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Re: On-going shop reorganization build thread [updated 11.28.16]
« Reply #34 on: May 14, 2016, 03:06 PM »
Small improvement to my rail storage, which had simply involved stacking them on top of one another above the workbench cabinet. It worked fine, but obviously, if I needed to grab the 75" rail, I had to take all the others down first

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So I took some small blocks of 8/4 white oak i had lying around and jigsawed some slots

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Realized as I was attaching them that I only needed two, since the longest rail remains on the bottom. They are much more accessible now

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Kapex KS 120 w/UG Cart and Extensions • CXS Set • T18+3 w/Centrotec Installer's Set • PDC 18/4 • TS 75 • TSC 55 • HKC 55 w/250, 420 and 670 FSK rails • Carvex 420 w/Accessory Kit • Domino 500 Set • Domino 700 XL • OF 2200 w/Base Accessory Kit • OF 1400 • OF 1010 • MFK 700 EQ Set • LR 32 • MFS 400 w/2000, 1000, and 700 extensions • Rotex 90 • Rotex 150 • LS 130 • ETS-EC 150/5 • ETS 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • DX 93 • RS 2 • HL 850 • Vecturo OS 400 • CT 26 w/Long-Life Bag • CT Sys w/Long-Life Bag • MFT/3

Offline ear3

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« Last Edit: May 20, 2017, 03:33 PM by Edward A Reno III »
Kapex KS 120 w/UG Cart and Extensions • CXS Set • T18+3 w/Centrotec Installer's Set • PDC 18/4 • TS 75 • TSC 55 • HKC 55 w/250, 420 and 670 FSK rails • Carvex 420 w/Accessory Kit • Domino 500 Set • Domino 700 XL • OF 2200 w/Base Accessory Kit • OF 1400 • OF 1010 • MFK 700 EQ Set • LR 32 • MFS 400 w/2000, 1000, and 700 extensions • Rotex 90 • Rotex 150 • LS 130 • ETS-EC 150/5 • ETS 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • DX 93 • RS 2 • HL 850 • Vecturo OS 400 • CT 26 w/Long-Life Bag • CT Sys w/Long-Life Bag • MFT/3

Offline ear3

  • Posts: 3289
Re: On-going shop reorganization build thread [updated 5.14.16]
« Reply #36 on: June 30, 2017, 07:26 AM »
I thought I had built in enough room for growth when I redid the cabinets, but over the past year my systainers have spilled over, both due to new Festool acquisitions and because I've been systainerizing my other tools.  Despite a concerted effort to weed out some of my older, no longer frequently used tools through resale or donation, it was starting to get crowded on the shop floor, with the sys-roll serving as an ad hoc systainer storage unit:

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The cabinets above the systainer ports were similarly stuffed to the gills:

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So I decided to squeeze a few more square feet out of the back cabinet and add some more systainer ports without sacrificing too much cabinet space.  Fortunately I had built everything using only dominoes for alignment and pocket hole screws as fasteners, so it was really simple to dismantle the top unit:

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I was able to trim and recycle most of this material, though I did have to get one more sheet of red oak ply and edge it with red oak hardwood to match.  I should note here that the HKC 55 was a real champ on this project -- the longer 670 rail was perfect for handling the 15 1/2" wide material out of which the cabinet is made.

With everything temporarily pulled out of the cabinets and on the shop floor, I was having flashbacks to the chaos that had prompted me to do the original reorganization:

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With the top cabinets disassembled, I took the opportunity to trim, notch and fortify the studs on the back gable -- the cabinet itself is plumb because of the base I built, but variations in the concrete floor and presumably the back wall made the cabinet butt into into the framing materials:

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I again dominoed and pocket holed everything -- some I was able to do on the floor:

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But a lot was done in situ perched on a ladder.  So for the systainer port expansion, I only had to make the top horizontal shelf and the dividers -- these were then just secured in place to the top of the existing systainer bay with dominoes and pocket screws:

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End result gave me room for the equivalent of another four Sys-5's with headroom to spare for handles or stacks of multiple systainers:
 
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The new cabinet configuration on the upper portion is roughly the same amount of square footage as before -- I didn't measure the difference, but I've been able to put (almost) everything back that was up there, and also took the opportunity to weed out a few more items that were just collecting dust:

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The cabinet is, however, 11 feet tall now, and so I am going to redo the 2x4 ladder to give me a few more feet so I'm not stretching above my head when I have to grab stuff from the very top.

As you can see, I've been able to squeeze just about every last square inch out of that back wall.
« Last Edit: June 30, 2017, 08:25 AM by Edward A Reno III »
Kapex KS 120 w/UG Cart and Extensions • CXS Set • T18+3 w/Centrotec Installer's Set • PDC 18/4 • TS 75 • TSC 55 • HKC 55 w/250, 420 and 670 FSK rails • Carvex 420 w/Accessory Kit • Domino 500 Set • Domino 700 XL • OF 2200 w/Base Accessory Kit • OF 1400 • OF 1010 • MFK 700 EQ Set • LR 32 • MFS 400 w/2000, 1000, and 700 extensions • Rotex 90 • Rotex 150 • LS 130 • ETS-EC 150/5 • ETS 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • DX 93 • RS 2 • HL 850 • Vecturo OS 400 • CT 26 w/Long-Life Bag • CT Sys w/Long-Life Bag • MFT/3

Offline HarveyWildes

  • Posts: 552
Re: On-going shop reorganization build thread [updated 6.30.17]
« Reply #37 on: June 30, 2017, 09:20 AM »
Looks like there is still a triangle about half way up the ceiling that you could use for maybe a #3 systainer.

I have this image of a systainer library with a rolling library ladder along the wall for reaching the high stuff.  It would only take a few tweaks to your 2x4 ladder.

On the ridiculous extreme, perhaps a "soda vending machine" mechanism that moves in two dimensions along the wall to retrieve the systainer that you want.  Then you just tell Alexa that you want systainer D-7 that's 9 feet up, and wallah!


Online Bob D.

  • Posts: 632
Re: On-going shop reorganization build thread [updated 6.30.17]
« Reply #38 on: June 30, 2017, 10:42 AM »
What comes in a Systainer with the carry handle mounted on the front?
Don't believe I have ever seen a Systainer with the handle on the front.

Middle column, half way down.
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It's a table saw, do you know where your fingers are?

Offline ear3

  • Posts: 3289
Re: On-going shop reorganization build thread [updated 6.30.17]
« Reply #39 on: June 30, 2017, 10:45 AM »
@Bob D.  It's an add-on accessory: https://www.amazon.com/Festool-497856-Auxiliary-Handle-Systainer/dp/B003ZX7UJS

Works for the smaller systainers when you want to carry them like a briefcase in a situation where you're only transporting a few to a job and don't need a sys roll or sys cart.

What comes in a Systainer with the carry handle mounted on the front?
Don't believe I have ever seen a Systainer with the handle on the front.

Middle column, half way down.
Kapex KS 120 w/UG Cart and Extensions • CXS Set • T18+3 w/Centrotec Installer's Set • PDC 18/4 • TS 75 • TSC 55 • HKC 55 w/250, 420 and 670 FSK rails • Carvex 420 w/Accessory Kit • Domino 500 Set • Domino 700 XL • OF 2200 w/Base Accessory Kit • OF 1400 • OF 1010 • MFK 700 EQ Set • LR 32 • MFS 400 w/2000, 1000, and 700 extensions • Rotex 90 • Rotex 150 • LS 130 • ETS-EC 150/5 • ETS 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • DX 93 • RS 2 • HL 850 • Vecturo OS 400 • CT 26 w/Long-Life Bag • CT Sys w/Long-Life Bag • MFT/3

Online Bob D.

  • Posts: 632
Re: On-going shop reorganization build thread [updated 6.30.17]
« Reply #40 on: June 30, 2017, 10:47 AM »
Oh, cool, mounts right in the label slots.

Very nice and smart thinking on Festools part.
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It's a table saw, do you know where your fingers are?

Offline Neal W

  • Posts: 107
Re: On-going shop reorganization build thread [updated 6.30.17]
« Reply #41 on: June 30, 2017, 01:19 PM »
A Question for my ignorance....

You used the LR-32 to pre drill holes to mount the drawer slides for the systainers, is this correct?
Turning perfectly good lumber into scrap and sawdust for more than 20 years!

Offline ear3

  • Posts: 3289
Re: On-going shop reorganization build thread [updated 6.30.17]
« Reply #42 on: June 30, 2017, 02:21 PM »
@Neal W That's right.  I only bothered to drill two columns of holes though, and used the 5mm vix bit to bore the center hole for the slides as needed.

A Question for my ignorance....

You used the LR-32 to pre drill holes to mount the drawer slides for the systainers, is this correct?
Kapex KS 120 w/UG Cart and Extensions • CXS Set • T18+3 w/Centrotec Installer's Set • PDC 18/4 • TS 75 • TSC 55 • HKC 55 w/250, 420 and 670 FSK rails • Carvex 420 w/Accessory Kit • Domino 500 Set • Domino 700 XL • OF 2200 w/Base Accessory Kit • OF 1400 • OF 1010 • MFK 700 EQ Set • LR 32 • MFS 400 w/2000, 1000, and 700 extensions • Rotex 90 • Rotex 150 • LS 130 • ETS-EC 150/5 • ETS 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • DX 93 • RS 2 • HL 850 • Vecturo OS 400 • CT 26 w/Long-Life Bag • CT Sys w/Long-Life Bag • MFT/3