On-going shop reorganization build thread [updated 7.18.20]

[ear3]

I've posted so many questions related to my shop reorganization that I decided it would be useful for me to just centralize it in a single thread and chronicle the ongoing changes.  Just to set the parameters, my workshop occupies one-half of a 2 car garage in what used to be my grandfather's, then my dad's, and now my house (which I share with my aunt -- 2 family upstairs/downstairs unit -- she gets the other half of the garage).  My dad originally setup a rudimentary workspace in the garage, and I've been gradually modifying it since I took over the house.  Since I started to convert my workshop over to Festool, I've found my conceptions of the workspace changing radically, and decided this past Winter to do a major overhaul.  This was the moment I realized something had to be done (taken last November, and chronicled here: http://festoolownersgroup.com/workshops-and-mobile-vehicle-based-shops/ideas-for-shop-reorganization/msg356395/#msg356395):

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I had just returned from an installation, and realized with disgust that I could barely navigate the space.  It was like playing a game of Tetris every time I wanted to access a tool or perform some operation.

My needs: Since I have the driveway, I will continue to do most of my cutting out there (miter saw, router table and table saw are all mobile), but I want the space to be as organized as possible, and have the option to do cutting inside when the need arises.  I mostly work on my own projects, but a few times a year I do art installations -- most of the work is done on-site, but there's usually a fair bit of prep work to do at home base, and so I need to have the capacity to temporarily store and process large amounts of lumber.

So here's what I've done so far.

I don't have a huge amount of hand tools, and so I realized they could be organized and stored more efficiently in a cabinet above the workbench with a hybrid pegboard construction (documented here: http://festoolownersgroup.com/workshops-and-mobile-vehicle-based-shops/shop-cabinet/msg399394/#msg399394):

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I realize I'm working a bit backwards by not re-doing the workbench first, but I'm still figuring out what I want for that, so the current bench is just a placeholder for what will eventually take its place.

In the meantime, I've gone to work clearing out the back to free up storage and make space for a chaos cabinet.  I redid and expanded the cordless tool storage station, and moved it to the right of the workbench:

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The loft on my side of the garage had accumulated 15 years of junk, and so I did a ruthless round of sorting and trashing over the weekend (thanks NYC Dept. of Sanitation!).  It's amazing how much junk one holds onto.  This allowed me to actually take out the back part of the loft:

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With the back loft out, it now became possible to use the front loft space more efficiently.  This is what it looked like after I had cleared all the junk:

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Now I have separate compartments space for long wide boards and guide rails, 2x4s and the long extension ladder, long narrow boards, and moulding/miscellaneous long pieces:

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Since I moved the cordless tool storage station, I could now move the drill press over to the left side of the bench, and thus take it off the back wall:

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I then simplified the wood storage on the left, designating it as a space for scraps under 4ft, but keeping the space underneath for sheet good storage:

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I can't help but feel like the old configuration is still exerting some influence over this redesign of the scrap storage, and that there might be more efficient ways of doing this, but I couldn;t think of any that would still allow me to put 4x8 sheets underneath.

So this is what the back wall of the shop now looks like, ready to receive a Chaos Wall:

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I've got my LR32 and am now working out the design of the Chaos Cabinet/Sys-ports, which I will embark on as soon as I pick up the drawer slides.  More to come...

 

[mike_aa]

Edward,
Wow, have you been busy and productive!  I really like your thought process.  Things are really shaping up.  I can't wait to see your chaos wall evolve.  Thank you for sharing all this.

Where did your table saw go?  Are you keeping it next to band saw at the front?

Thanks, Mike A.

 

[ear3]

Thanks!  TS and BS still there, they were just wheeled out of the way temporarily.

 

[HDClown]

I like that cordless tool rack... need to build one of those so my drills don't need to waste a bunch of space in my rolling tool box.  Anything unusual about the once you built you can't see in the picture?  Seems pretty straight forward.

 

[ear3]

Do you mean the over-the-workbench cabinet?  I got the idea from Shop Notes magazine, and posted build pics here: http://festoolownersgroup.com/workshops-and-mobile-vehicle-based-shops/shop-cabinet/msg399394/#msg399394

I like that cordless tool rack... need to build one of those so my drills don't need to waste a bunch of space in my rolling tool box.  Anything unusual about the once you built you can't see in the picture?  Seems pretty straight forward.

 

[HDClown]

Do you mean the over-the-workbench cabinet?  I got the idea from Shop Notes magazine, and posted build pics here: http://festoolownersgroup.com/workshops-and-mobile-vehicle-based-shops/shop-cabinet/msg399394/#msg399394

I like that cordless tool rack... need to build one of those so my drills don't need to waste a bunch of space in my rolling tool box.  Anything unusual about the once you built you can't see in the picture?  Seems pretty straight forward.

Naw, the cordless tool storage piece that's to the right of that, with the hanging drills, M12 stuff, and chargers on top.

 

[ear3]

Got it.  Yeah, really straight forward.  Some people do variations where they use what looks like PVC, which looks kind of cool:

https://www.google.com/search?q=cordless+tool+storage&biw=1366&bih=609&source=lnms&tbm=isch&sa=X&ei=kV93Vb-NGcSXyATYlYHAAw&sqi=2&ved=0CAcQ_AUoAg

Since I had a lot of non-drill cordless items, I just went with the more simple slot design that I also use for the clamp racks

 

[Billedis]

Nice job, looking forward to the chaos wall build!  Thanks for sharing.  Bill

 

[JonSchuck]

The first thing I would do would be to insulate.  Maybe it's just me but I'm a hobbyist and if I can't be comfortable it wouldn't be fun.  But if you can enjoy cutting wood in your driveway in the winter, more power to you.

 

[ear3]

I've finished the first part of the chaos wall build, the systainer section.  Since I have such a tall space, and it will be irregular lengths due to the roof slope, I decided to break it up into two sections with separate building processes: systainer storage on the bottom, and then later on more traditional cabinets/shelves on the top.

There were a few trade-offs in choosing the design and hardware:

1) Originally I was thinking of making the wall deep enough for two systainers per shelf.  But doing so would have mandated premium drawer slides, and I was not sure I wanted to sacrifice 28"+ of depth.  Since I relocated the drill press to the side of the workbench, I actually ended up having enough room along the back wall for 4 columns, so I felt like I would be fine just to go with one deep.

2) I settled on 73 3/4" x 72" x 15 1/2" as the size for the systainer storage cabinet (for depth 15 1/4" ply + 1/4"oak cap).  Any deeper and I would have pushed up the materials cost, since I would have only been able to get 2 lengthwise cuts rather than 3 from each sheet.  This meant, though, that I went with...

3) ...14" three-quarter extension epoxy drawer slides.  Got a really good deal on them at less than $2 a pair, but at this size they don't allow me to open the systainers lids fully while they're still on the shelf.  That doesn't seem like a big sacrifice at the moment, but maybe down the road I'll swap out the slides for some pricier 14" metal full extension ones that would allow opening the systainer tops in place. 

As for the build, got to use a full range of tools.  The edging plate for the 1010 makes flush-trimming the oak caps a quick and precise operation:

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RO150 and RTS400 cleaned the rest of the glue and edges:

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I routed the verticals on every other index hole with the LR32.  Just did the front and back holes (for accepting euro screws), and went with the Centrotec 5mm self-centering bit to fill in the center holes when needed during the actual assembly ($81 -- yikes!  I was in a rush so just went to a local Festool dealer instead of waiting a few days for a Vix or a Snappy to come by mail):

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For assembly, I went with a combination of dominoes and pocket screws, using the former for purposes of alignment:

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And the pocket screws for securing the boards once they were in place (for securing the top I just went with screws straight down into the verticals, since this part will eventually be covered with the top half of the shelf):

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Not quite as slick as the Hafele connectors I guess, but the actual assembly was still pretty quick.  First the 2x4 base leveled with shims:

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Then started putting up the boards:

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Used two pocket-holed cross pieces per column in the back to maintain a consistent width all the way down the column and also secure the cabinet to the back studs:

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Here's the case with all the systainers on their shelves --  I left some room for future growth and for slotting in other tools/fasteners/accessories:

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I haven't decided how I will do the front edge/lip of the shelves.  I experimented on a few of them with some 1/8" oak scrap I have lying around.  I'm going to sleep on it and get back to work tomorrow.  Thanks again to everyone who answered questions and/or provided encouragement on the project.

 

[Billedis]

Nice job.  Thanks for sharing.  Bill

 

[mike_aa]

Edward,
Terrific build!  Nice way to economize on the amount of material needed. 

Since you did not use the knock down fittings, if you ever have to move this to another location, are you able to unscrew the pocket screws and reuse them?  That's assuming you did not use glue on the dominos.

Whenever (and if) you decide to switch out you runners, erock referenced some economical full extension ones in reply #29 in his thread on making sysports.  He got them off eBay.

Thanks, Mike A.

 

[Mikeyfondu]

Great work Edward! being organized is a beautiful thing ! I have two stacks of systainers on Rolling base , but this wall may be in my future
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[ear3]

Wow, that is a good price for the slides.  I may have to swap out sooner than I expected.

I didn't use glue so I have the option of quickly breaking it down and shifting it around.  Sometime in the future I will end up getting the whole garage space, rather than just the current one half allotment, so I will eventually have options for more expansion.  But since that hinges on someone else's mortality, I neither wish for it nor even feel good mentioning it, so we'll just leave it at that.  That's basically the reason -- to respond to a previous comment -- why there's no insulation/finishing in the interior, as it would have been a vain effort to only do it to one side.
   
Just finished up the front edges of the plywood shelves, and am taking a break to play some chess.

Edward,
Terrific build!  Nice way to economize on the amount of material needed. 

Since you did not use the knock down fittings, if you ever have to move this to another location, are you able to unscrew the pocket screws and reuse them?  That's assuming you did not use glue on the dominos.

Whenever (and if) you decide to switch out you runners, erock referenced some economical full extension ones in reply #29 in his thread on making sysports.  He got them off eBay.

Thanks, Mike A.

 

[ear3]

I've put up the higher shelving.

Ended up with just two columns.  The one on the left is a fixed shelf -- there seemed to be no point of putting shelf-pin holes since the bottom section was dedicated to house the Leigh D4R, which left only about 12 inches of space in the upper half.  I did put pin holes on the right, though, with the LR32, including a line of holes in the middle in case I wanted to put in a shallow shelf to make room for extra tall objects.  Width of this column is 2 feet.  I ended up not running it the full length of the bottom unit to give a little extra space to ascend the ladder and to pull down long objects from the loft.  I may end up putting doors on the upper unit, but for now I'm going to leave it as is.  I figure that now that everything is up high, there will be less dust accumulation, and what does gather can be quickly vacuumed off.

Construction was the same -- combination of dominoes, pocket screws, and straight screws through the top (no glue):

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I decided to follow the original chaos wall specs more closely on the upper shelves, and so routed a dado for a 5mm backing:

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Having the right angle chuck was a huge plus for securing the top:

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Shelf is complete and ready to be filled:

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Was surprised with how much less stuff I had once it had been sifted through and all organized:

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View from the front, now with a clear path all the way to the back:

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[Billy stray]

looking good , maybe your aunt woul like a lovely hand crafted carport  [wink]  [wink] ....J/K

 

[mike_aa]

Edward,
Wow, that really makes excellent use of your space!  Even though you had to follow the roof line along the top, it appears the extra shelves are stowing a good amount.  Nice work.  You put my own feeble attempts at organization to shame.  LOL!

Now that everything is all stacked up so neatly and more visible, have you given any thought to security issues since this is in a garage with a now clear path to the back wall?

Thanks, Mike A.

 

[John Beauchamp]

Something I don't understand. You have spent thousands on Festools but decide to cheapen up on your project using 3/4 slides instead of full extension. It's your money and your project and if you're happy I'm happy but I have noticed this with others who buy expensive tools and then won't spend the money on materials to do the job the way they really want but will cut corners to save money. Where is the balance.

 

[ear3]

Funny you should mention.  My track saw woke me up this morning and started complaining about the fact that I had used scraps of construction grade plywood on a couple of the pull-out shelves, and how his life sucked because he ended up with such a cheap SOB as an owner.  He's now threatening to walk and take the Rotexes with him unless I redo the shelves in QSO, and to make up for the indignity of the slides, he also wants me to swap them all out for the SYS-AZs. 

Something I don't understand. You have spent thousands on Festools but decide to cheapen up on your project using 3/4 slides instead of full extension. It's your money and your project and if you're happy I'm happy but I have noticed this with others who buy expensive tools and then won't spend the money on materials to do the job the way they really want but will cut corners to save money. Where is the balance.

 

[ear3]

Few more modifications on the shelving.

Added some doors on the left column in order to at least keep the dust off the Leigh Jig and some of the sharpening equipment.  Also added some quick drawers in the systainer section to consolidate some of the loose tools, rather than devote separate small pull out shelves:

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Used the European cup hinges on the doors -- first time using them, and I like the adjustability:

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Finished off the doors by turning some leftover cherry for the knobs:

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Now I'm working on redoing the stand for my lathe, which I should be finished up with tomorrow.