Author Topic: On-going shop reorganization build thread [updated 6.18.19]  (Read 35496 times)

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Offline ear3

  • Posts: 3884
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-EC 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • RS 2 • HL 850 • Vecturo OS 400 • CT 26 w/BT module • CT Sys w/Long-Life Bag • MFT/3

Offline ear3

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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-EC 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • RS 2 • HL 850 • Vecturo OS 400 • CT 26 w/BT module • CT Sys w/Long-Life Bag • MFT/3

Offline Billy stray

  • Posts: 317
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-EC 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • RS 2 • HL 850 • Vecturo OS 400 • CT 26 w/BT module • 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-EC 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • RS 2 • HL 850 • Vecturo OS 400 • CT 26 w/BT module • 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-EC 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • RS 2 • HL 850 • Vecturo OS 400 • CT 26 w/BT module • CT Sys w/Long-Life Bag • MFT/3

Offline ear3

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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-EC 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • RS 2 • HL 850 • Vecturo OS 400 • CT 26 w/BT module • CT Sys w/Long-Life Bag • MFT/3

Offline HarveyWildes

  • Posts: 848
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!


Offline Bob D.

  • Posts: 1253
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.
-----
It's a table saw, do you know where your fingers are?

Offline ear3

  • Posts: 3884
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-EC 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • RS 2 • HL 850 • Vecturo OS 400 • CT 26 w/BT module • CT Sys w/Long-Life Bag • MFT/3

Offline Bob D.

  • Posts: 1253
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.
-----
It's a table saw, do you know where your fingers are?

Offline Neal W

  • Posts: 126
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

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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-EC 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • RS 2 • HL 850 • Vecturo OS 400 • CT 26 w/BT module • CT Sys w/Long-Life Bag • MFT/3

Offline ear3

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Re: On-going shop reorganization build thread [updated 6.30.17]
« Reply #43 on: April 28, 2018, 09:12 AM »
Last summer I upgraded my planer from the Dewalt 734 to the 735 -- I stumbled across a good deal on Craigslist and decided to jump at the opportunity, primarily so I could add the Shelix cutterhead and make planing a little less noisesome for me and my neighbors (and get a great finish on my boards along with a durable cutters to boot!).

I had been storing my 734 under my lathe stand, but since the Craigslist deal came with the stand included, and because the 735 is heavier and bulkier than the older model, I decided to just keep the stand and move it around in my narrow shop as needed.

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It has worked out so far, but it has been a bit of a nuisance having the stand in the way all the time.  I was considering adding some additional storage capacity to the Dewalt stand, like I've done with my Kreg router table, but because of how wide the leg profiles, I rejected that option and recently decided to build my own mobile stand with integral storage.

I'll just show a few finished or near-finished pictures since the design/build is so basic.  I had to buy an extra piece of 8/4 white oak, but for the most part was using up extra material I had lying around my shop (which is why I mixed in the red oak ply for the top and the drawer sides/back).

Basic frame and panel construction using 12mm dominoes and a dado/groove to fit the 5mm plywood panel.  The drawers sit on 3/4" white oak frames that rest on supports pocket screwed into the inner part of the frame, as you can see in this picture I took while routing out a rabbet on the back for the back panel (the drawer frames are in addition pocket screwed into the legs from the underside):

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I didn't feel like buying drawer runners, so I just built in a center guide on the underside of the drawers and the drawer frames:

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Drawers extend all the way to the back of the caracasse:

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And here's the front of the stand prior to finishing (I used solid 3/4 white oak for the drawer fronts):

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I did add some white oak edge banding to the tops of the ply on the drawer sides and back, as well as around the top.

Wheels are just 3" locking casters sourced from my local HD.  Also added some cheap handles that I had bought last year for another cabinet but ended up not using.  Finished it with Surfix heavy duty oil, and block planed a slight chamfer on the drawer fronts.  The top, which is simply screwed into the stand, has holes added for the bolts to secure the planer, and the 1/4 back panel has been fitted flush into the rabbet and pinned:

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The advantage of this stand over the Dewalt metal one, in addition to having integral storage, is that the wheels make it fully 360 degree mobile.  I sized the stand so that I have the option in the future to build into the back a collapsable extension for when I'm planing longer boards, similar to what I did on my Kapex cart.  But for now I will continue to rely on the metal extension tables that I got with the planer.

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Now I have to figure out what to put in the drawers -- it will not be a problem filling them, but I want to figure out the most efficient use possible of that space, since my shop is currently stuffed to the gills.

BTW, I've put the Dewalt metal stand up on Craigslist NYC in case anyone in the area is interested -- I'd be more than happy to add in a FOG discount: http://festoolownersgroup.com/classifieds/dewalt-planer-stand/
 
« Last Edit: April 28, 2018, 09:19 AM by ear3 »
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-EC 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • RS 2 • HL 850 • Vecturo OS 400 • CT 26 w/BT module • CT Sys w/Long-Life Bag • MFT/3

Offline jobsworth

  • Posts: 5785
  • Festool Baby.....
Re: On-going shop reorganization build thread [updated 4.28.18]
« Reply #44 on: April 28, 2018, 01:15 PM »
Looks like your shop is coming along nicely

Offline Picktool

  • Posts: 132
Re: On-going shop reorganization build thread [updated 4.28.18]
« Reply #45 on: April 30, 2018, 09:27 AM »
If Ed gets any more tighter fitting in there with the tools,
he'll be posting the addition of a 4x4 CNC ??  [wink] I see it coming.

What size space is that... 12x20?
Well Dogey

Offline ear3

  • Posts: 3884
Re: On-going shop reorganization build thread [updated 4.28.18]
« Reply #46 on: April 30, 2018, 10:48 PM »
@Picktool Close!  It's 20x8.  But the 13" height of the roof peak makes all the difference, affording space for a loft to store lumber and other bulk items, and allowing me to maneuver tall, unwieldy things when needed in and out of the space.

If Ed gets any more tighter fitting in there with the tools,
he'll be posting the addition of a 4x4 CNC ??  [wink] I see it coming.

What size space is that... 12x20?
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-EC 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • RS 2 • HL 850 • Vecturo OS 400 • CT 26 w/BT module • CT Sys w/Long-Life Bag • MFT/3

Offline ear3

  • Posts: 3884
Re: On-going shop reorganization build thread [updated 4.28.18]
« Reply #47 on: June 18, 2019, 09:46 AM »
After 4 years of faithful service, my workbench cabinet is being retired.

While it was good for what I needed at the time, the pegboard configuration meant that it was primarily a hanging tool cabinet.  As I've been shifting my carpentry toward a greater reliance on hand tools over the past few years, I've run out of space for the gear that I've been integrating into my arsenal.

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It also doesn't help that I hold on to legacy tools that I rarely if ever reach for -- so the new cabinet will also be an opportunity to clean house of the stuff that doesn't get used.

The logjam has also frankly become a stumbling block to my work.  I've had to stuff tools anywhere I could find room -- behind the lathe, under the router table, in empty systainers -- and not having immediate access to some of them means that I don't keep all of them tuned up and ready to go.  I've retained easy access to all of my bench planes throughout, and so have been able to develop some facility with them and make determinations on the fly whether, say, a no. 6 or a no. 7 is working best on a particular task, but with some of the more specialized planes, because many of them reside away from the bench, it's not as easy to just grab one and measure its relative performance.

The overall dimensions of the new cabinet, made in maple and Baltic Birch rather than poplar, were roughly the same as the old one: 76" x 32" x 7 1/4" (vs. 76" x 29" x 7" for the old one) -- but I gain some internal space by not having to factor in a 3/4" spacer on the back to offset the cabinet from the wall, as I did on the old one to permit proper functioning of the pegboard.  I've also retained the sliding door feature of the old one that I find to be incredibly useful.  My shop is such that when I'm working on big projects, I sometimes have to keep things on the bench, and so a hinged door design of a more traditional handtool cabinet would limit access in certain situations. 

Nothing fancy about the carcasse construction -- just 4 fixed verticals dominoed into the tops and bottoms, with 1/2" Baltic Birch set flush into a rabbet on the back.

I did use a method on the glue up which I've been doing more recently, which is to blue tape at the glue joint:

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It does take more time on the front end doing all the dry fitting and taping, but you recoup most if not all of it on the back end by not having to scrape or sand the glue out of the joints:

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I did the rabbet after the fact, riding the 1010 precariously along the 11/16 boards:

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And then finished up by hand around the verticals by sawing out the bulk and then using a shoulder plane to even the line:

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Even got to use my Clifton 3in1 combination plane to do the corners, which was one of the very first planes I got, but remains one of the least used:

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I dominoed a face frame to the carcasse to act as the front track for the sliding doors:

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And then nailed in 1/2" maple strips on the top and bottom of the case to complete the track, insetting them into notches I had made into the verticals at the front.  Although the doors worked great on the first cabinet, I added UVHM tape to the track and at various strategic points on the new one to make the action even smoother:

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The doors, which are just a frame and 1/4" BB panel construction, slide incredibly smoothly now:

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My neighbor has inherited the old cabinet.  Thanks to Festool, he also has a serviceable shop filled with my old tools purchased in the 2000s, such as a Ridgid chopsaw, Ryobi portable table saw, oldstyle Dewalt 18V drills.

Next up, putting in the tools
« Last Edit: June 18, 2019, 11:37 AM by ear3 »
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-EC 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • RS 2 • HL 850 • Vecturo OS 400 • CT 26 w/BT module • CT Sys w/Long-Life Bag • MFT/3

Offline ear3

  • Posts: 3884
Re: On-going shop reorganization build thread [updated 6.18.19]
« Reply #48 on: June 18, 2019, 10:26 AM »
A tool cabinet is incredibly personal, where tool selection and placement is a reflection of the specific kinds of work you do.  This is what makes pegboard so ingenious, because it allows an endless amount of reconfiguration as your priorities and habits shift, permitting the cabinet to evolve as you do.  And within a certain range of tools, there's basically no chance of making a mistake or limiting yourself in the future, because you can just move the tool you no longer use from its prominent place and shift it to the back.

Although I'm by no means done acquiring new tools, I felt like I was ready to make the switchover to a fixed back cabinet because I have assembled a core set of handtools at this point that won't change in the future.

It's a different experience staring at the empty plywood back of a pegboard-less tool cabinet.  I looked at it for over a day as I procrastinated doing other trivial stuff around the shop, wondering where to start and worried that the choices I made at the outset would create a path dependence leading to severe underutilization of the available space.  The only thing that I had determined from the outset was where the bulk of the handplanes would go.  I made the left hand bay wider than the others, and made sure in the cabinet design to have at least a 5 1/2" clearance between the back and the doors so that my bench planes could fit vertically:

299311-0   

The other main difference from a pegboard cabinet is obviously that you have to make all the toolholders yourself.  So this project has become a nice way of reducing the scrap and offcut stockpile in my shop.

I'll spare you the complete, tedious blow by blow account of toolholder manufacture and just do a few highlights.  After much brow furrowing, I decided to start with the easiest and make the chisel holder, since this could be moved around as needed if I later on became dissatisfied with its placement.  I fortunately have a bunch of curly maple offcuts that will provide some flair for the cabinet:

299313-1

A real workhorse on this project has been the LN 102 Block Plane which I only acquired about 2 months ago, but which has already become one of my favorite planes.  I did all the chamfering of the toolholders and cabinet with it:

299315-2

299317-3

The cool thing about making the toolholders is that some of the tiniest details end up making all the difference.  Like these holders I made for my combination squares, a tiny 1/8 cube glued on the edge helps ensure that the squares, which are mounted on one of the sliding doors, don't fall off as the door is moved back and forth:

299319-4

299321-5

It takes time though to make them all of the toolholders individually.  Like the ones for the saws, you have to trace and cope out the basic shape:

299323-6

299325-7

Then rasp and sand to final fit:

299327-8  299329-9 299331-10

Especially excited that I got to use up some of the remaining scrap from the maple conference table I built a few months ago, and convert it into the door handles:

299333-11 299335-12 299337-13

Next up, the handplane till.
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-EC 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • RS 2 • HL 850 • Vecturo OS 400 • CT 26 w/BT module • CT Sys w/Long-Life Bag • MFT/3

Offline ear3

  • Posts: 3884
Re: On-going shop reorganization build thread [updated 6.18.19]
« Reply #49 on: June 18, 2019, 10:56 AM »
The handplane till has proven to be the biggest challenge so far.  I started off doing a vertical configuration for the longer nos. 7 and 8:

299339-0

And was going to continue in that vein, though preserving a space at the bottom for some drawers for small parts and blades.  But the differing widths of the various planes made me switch over to doing a horizontal placement, reserving space at the top for spokeshaves and similarly odd shaped items:

299341-1

I was building the 1/2" shelves level by level, dryfitting them initially with 4mm dominoes.  I did this so that I could have shelves of varying width -- but after I had it all setup I realized that I wasn't gaining anything by having narrower shelves, as there wasn't anything of substance I was going to be able to fit along the sides of the cabinet even with this configuration.  So I scrapped that idea and instead glued up a fixed shelf cabinet all at once, where the top shelves were notched at the back so I could nestle the toe of certain planes for extra security:

299343-2

The advantage of doing all the shelves equal to the internal usable depth of the cabinet was that it gave some extra space to fit some of the smaller planes, which would otherwise be a nuisance around which to build a dedicated spot.

In order to make it more than a utilitarian build, I decided to use a nice piece of curly maple for the drawer faces, where the drawers would preserve a continuous grain of the original board.  I had one piece that has been sitting in my lumber loft for a few years, and which I've never used because it is so warped:

299345-3

Even after cutting a small section out of it, I had to joint a significant twist and a bow:

299347-4  299349-5

But running it through the planer showed that this particular board was worth the effort:

299353-6

The drawers were just a simple mitered box construction, punched out on the table saw, with the lower drawers notched to provide clearance for the drawer runners I installed on the shelf:

299355-7  299357-8

Turned some wenge scrap for the drawer pulls, the posts of which I pounded through a dowel plate for an even fit:

299359-9  299361-10

Really happy with the final result:

299363-11

I have a habit of making drawers that are too big, and thus wasting a bunch of space, so I'm also happy to have made something so compact that gives me a few different spots to store stuff.

So this is where I'm at now:

299365-12  299367-13  299369-14

Almost all the planes have a home, and the middle bay is mostly open for more tools.  Although the tool configuration in the right bay might seem inefficient at first glance, I'm going to be adding a hanged internal door about midway deep so I can put in additional toolholders, and thus have two levels in operation.

I welcome any suggestions you might have for better or more efficient placement.

« Last Edit: June 18, 2019, 11:02 AM by ear3 »
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-EC 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • RS 2 • HL 850 • Vecturo OS 400 • CT 26 w/BT module • CT Sys w/Long-Life Bag • MFT/3

Offline ear3

  • Posts: 3884
Re: On-going shop reorganization build thread [updated 6.18.19]
« Reply #50 on: June 23, 2019, 12:08 AM »
Pretty much finished up on the cabinet for now.  Which is a good thing, as my shop has been turned upside down for almost two weeks while working on this, and has prevented any other work from happening while going on.

The plane and chisel storage were relatively easy compared to the rest of the tools, which had a wide range of shapes and dimensions making standardization difficult.  Most of that stuff I ended up locating in the middle bay, paring down to the most frequently used miscellaneous hand tools, and placing the rest in drawers.    I did take a short cut in the middle bay for the pliers by adding in a magnetic tool holder rather than trying to shape wooden tool holders -- it just would not have been efficient to try to hang them individually.

I had a lot of fun making the holder for the scorp in the upper righthand corner of the right bay (shown in close up in the last three images).  I considered not dedicating space to it in the cabinet, since I don't use it very often, but it's not the sort of thing that's very practical to stick in a drawer.  I traced out the concave and convex the shape of the blade onto two plywood templates that I then routed into some maple scrap.  The top piece is 1 1/2" thick so that the blade is fully protected.

I don't really have much room left.  A few more items can go on the right door, and then I will add a hinged partition in the right bay to accommodate an additional layer of chisels, but otherwise, any additions will have to be made by moving out tools into other spaces.   
 
« Last Edit: June 23, 2019, 07:59 AM by ear3 »
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-EC 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • RS 2 • HL 850 • Vecturo OS 400 • CT 26 w/BT module • CT Sys w/Long-Life Bag • MFT/3

Offline ear3

  • Posts: 3884
Re: On-going shop reorganization build thread [updated 6.18.19]
« Reply #51 on: June 26, 2019, 05:59 PM »
Few more minor improvements I just wanted to document.

The biggest one is the addition of a swinging door in the right bay so I can fit another run of chisels.

I still had pieces of the curly maple I used for the drawers, so I took one and resawed it with my Roubo frame saw (running in a kerf made with the table saw) to form a bookmatched center panel for the door:

299837-0  299839-1

I kept the pieces clamped flat while the moisture readjusted in the boards, but probably should have kept them flat a bit longer, as the resulting panel (glued up after the boards were jointed and thicknessed) still had a twist to it:

299841-2

Not a huge deal though -- at 1/4", the panel is thin enough to bend into the slot I made in the frame, joined together with 6mm dominoes:

299843-3

Mortised out the hinge placements with the router plane on both the door and a 5/8th strip that gets attached to the cabinet

299845-4

299847-5

I used Brusso stop hinges (JB 103 if anyone's curious), which Tools for Working Wood in Brooklyn carries.  I didn't know the price before walking them up to the register, and my eyes almost popped out when they rang me up for $62 for two packages.  Well, at least they look good:

299849-6

And for that price I assume they will last the life of the cabinet.  I fortunately had made a few extra wenge door pulls, which, because I now have more drawers for holding small odds and ends, I had stored away just in case -- so I added one to the swinging door.

299851-7  299853-8

I will probably make another door at some point for that lower half of the right bay, but will wait until the tools requiring it show up.

I'm proud of the holder I came up with for my bar gauge, which up until now has lived in the drawer with my pneumatic nails.

Stuck two scrap blocks together with double-sided tape, drilled 3/8" holes that I opened to the edge with a saw, then worked with the spindle sander to ensure proper clearance:

299855-9

The holes sit slightly lower than the channel so that gravity holds the bars in place.

Added some grooves to the top where the actual gauge would sit, then flushed the backs on the shooting board:

299857-10

Here's the holder on the right door panel:

299859-11

I 2P-10'ed a thin strip on the outside of either block so that the bars don't slide back and forth when the door moves.  I may try to redo it in the future so that I can fit two bars on each level, thus making for a more compact footprint, but for now this will do.

Finally, I'm also continuing to tweak things here and there to add a few extra square inches of space or take advantage of a nook.  I added some holders to the top of the cabinet to fit my 24" straightedge that I use all the time when jointing boards:

299861-12  299863-13

Also moved the large bench planes up a few inches to give clearance for my small planes, which are now protected by a tiny shelf on which I can set thin items that won't interfere with removing and putting back the large planes:

299865-14
 
« Last Edit: June 26, 2019, 06:16 PM by ear3 »
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-EC 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • RS 2 • HL 850 • Vecturo OS 400 • CT 26 w/BT module • CT Sys w/Long-Life Bag • MFT/3

Offline neilc

  • Posts: 2727
Re: On-going shop reorganization build thread [updated 6.18.19]
« Reply #52 on: June 26, 2019, 06:30 PM »
Edward

Fantastic review of your thinking and build. The maple cabinet looks great!  It should be an heirloom with all the tools being custom fit to it!

Offline rvieceli

  • Posts: 1043
Re: On-going shop reorganization build thread [updated 6.18.19]
« Reply #53 on: June 26, 2019, 06:40 PM »
Very nice Edward.

Offline ear3

  • Posts: 3884
Re: On-going shop reorganization build thread [updated 6.18.19]
« Reply #54 on: June 26, 2019, 06:48 PM »
@rvieceli and @neilc Thanks guys!
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-EC 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • RS 2 • HL 850 • Vecturo OS 400 • CT 26 w/BT module • CT Sys w/Long-Life Bag • MFT/3