There are a few things particleboard is NOT. It’s not medium density fiberboard (MDF)—a material with greater density and weight composed of more uniform particles. It’s NOT oriented strand board (OSB), a material composed of large wood chips and strands that’s structurally equivalent to plywood. It does NOT have great nail or screw holding ability, nor is it all that water resistant; water can quickly cause the material to swell and lose structural integrity. But if you need something flat and cheap for use in a dry place, particleboard will do you proud. Learn how to make a plastic laminate tabletop with a particleboard substrate.
Since most of your assembly will be done on the assembly table, it just makes sense to have your clamps nearby. If you’re short on wall space, try a rolling clamp cart! If you use your workbench for assembly, keep your clamps near the workbench. Check out these two helpful articles for clamp racks: A Simple Utilitarian Clamp Rack and A Parallel Clamp Rack.
Softwood is most commonly found in the regions of the world with lower temperatures and is typically less durable, lighter in weight, and more vulnerable to pests and fungal attacks in comparison to hardwoods. They typically have a paler color and a more open grain than hardwoods, which contributes to the tendency of felled softwood to shrink and swell as it dries. Softwoods usually have a lower density, around 25-37lb/cu ft, which can compromise its strength. Density, however, does vary within both softwoods and hardwoods depending on the wood's geographical origin and growth rate. However, the lower density of softwoods also allows it to have a greater strength with lighter weight. In the United States, softwoods are typically cheaper and more readily available and accessible. Most softwoods are suitable for general construction, especially framing, trim, and finish work, and carcassing.
Basically, I created a linear outfeed area, which includes the miter-saw station with folding wings, tablesaw with folding outfeed table, and my large router table, all in a line along the 20-ft. wall and set at the same height. The miter-saw station converts easily for use with a mortiser—with workpiece support on both sides—and it also accepts a minilathe. I even planned a location for all of the tools, blades, and jigs used with the tablesaw: on the operator side, for easy access.
The number of windows, as well as their sizing and placement, depends on your orientation, view, desire for ventilation, and needs for daylight and solar gain. Orienting more of your windows towards the south side of your shop and placing them high enough that they are shaded by the eaves in summer, but allow lower-angle winter light to come in, will increase your ability to get free light and heat from the sun. If your goal is to take advantage of passive solar opportunities, make sure that you carefully research the type of glass that is in your windows and look for something with a high solar heat gain coefficient. Higher windows generally allow for benches and tools beneath them, and relatively windowless north walls may be a place to arrange wood storage or mechanicals.
Keep in mind, there are no perfect boards, but try to always use the straighter boards and avoid warping boards. Also, Brandon and I have found that when it comes to picking out lumber at Home Depot and Lowes, they tend to stock up on fresh boards a few days before the weekend starts (so Thursday/Friday). And then, on Sundays and Mondays, the boards are usually really picked over and there isn’t a good selection. Just another tip to keep in mind!
I mix a lot of epoxy in small batches, but I’ve seldom had the right size container on hand. I solved this problem by drilling 1-1/2-in. holes in 2×4 scraps with a Forstner bit. The resulting shallow “cups” allow easy mixing without the risk of spilling. When the holes are used up, I just make a new mixing board. — Bill Wells. Save your takeout utensils to use in the shop!
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Along the opposite long wall are the planer, combination sander, drill press, bandsaw, workbench, and compressor. Each tool has dust-collection hookups and storage space to keep the relevant tools, bits, blades, and fixtures nearby. The planer is the only tool I have to roll out into the middle of the room to use, which takes about a minute, including connecting the dust-collection hose.
In most small shops, once the key machines are in place, others are arranged wherever there is room for them. There typically isn’t enough free space for these tools in the middle of the floor area, although sometimes you can tuck a machine into an unused space. For example, in a shop where the table saw is in the center, a shaper (or a router table or spindle sander) with a table the same height as the saw can be put on the outfeed side of the extension table (see the illustration). Also, building a router table directly into the table saw’s extension table is a great way to save space, as well as make use of the saw’s fence for routing operations.