My shop consists of a 9×16 storage building, with 3 feet being used for actual storage! I have a table saw, 13″ planer, lathe, sliding mitre saw, home made router table, small compressor, 5′ 4 drawer bench with vice, table top drill press, 6″ jointer, band saw, shop vac, wall mounted hand tool storage, clamp rack, power tool storage, and no room to turn around! But I put out a few nice pieces! Recently built, a 48″ entry table from 100 yr old milled poplar, coffee table from the same re milled red oak barnwood, and a little triangle shaped corner table from the left over red oak, a 7′ x48″ bookcase from old poplar, a small wall mounted poplar book case, and am presently working on a queen sized bed with a mixture of 100 yr old oak and new kiln dried oak, with drawbored pegging using black walnut from a tree from my yard! I’ve also made several mallets that I find useful from my firewood pile using Cherry, ash, hickory and white and red oak. Building anything in 108 sq ft is a challenge, but patience determination, and decent sales will make it work! One good point is that nothing is out of reach! Except maybe the bathroom!
One of the misconceptions about planers is that they make lumber straight. They do some straightening, but they don’t make lumber straight. That is what jointers do. Many lumber mills just send rough lumber through the planer allowing the board to exit the machine with the same ups and downs and whoops that is entered with, only now to a consistent thickness. This is especially apparent when gluing up a couple of these roller coaster type of boards and trying to get them to line up. After a couple of those glue-ups, you will swear by lumber that has seen the jointer before the planer, and never skip the jointer.
While trying to trace an exact copy of the throat plate for my table saw, I came up with this nifty technique using an ordinary pencil. I just shaved my pencil into a half-pencil by carefully grinding it on my belt sander. The flat edge enables my modified pencil to ride straight up along the edge of the template. It also works great for marking and then shaping inlays for my woodworking projects. — Tim Reese. How to cut circles with a band saw.
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Is your cellar damp? If so, you may have to correct that problem before installing your tools and lumber supplies. Insulate pipes to prevent condensation. Make sure your gutters outside keep rainwater running away from the house. Cracks in the cement floor or walls should be filled with hydraulic cement; a high water table may necessitate a sump pump to collect water at a low point and pump it out. Any or all of these circumstances may also require a dehumidifier. In any case, dampness is unacceptable where power tools are to be used because of the risk of electric shock.
If you work with rough lumber, a planer will be absolutely necessary, except for the most rustic of projects. Every piece of rough cut lumber ends up somewhat not straight, not flat and not consistent in thickness, either from variations during the sawing or from stresses which occur while the wood dries. The planer, combined with the jointer, is a one-two punch to remove these variations and produce straight, flat and consistently thick lumber. The reason the planer is ahead of the jointer on this list is that some lumber is straight enough and flat enough to plane without jointing if the job is a little less finicky, thereby skipping the jointer.
When you design your workshop setup, climate control often gets ignored — and that’s a huge mistake! If your workshop or hobby room is in an unconditioned space like a garage or basement, you could find that it’s brutally uncomfortable to work in there during warm weather. You’ll be much happier with a solid fan — or several — to keep air moving for your comfort.
Hard to determine which stain you need in that bespattered collection of cans? An easy-to-make “stain index,” courtesy of reader Bob Jacek, solves the problem. Section off boards of your favorite woods into squares with masking tape, and apply the different stains across the width of each wood type (pine, oak, birch, etc.). When the stains are dry, brush on lengthwise your regular ﬁnishes—polyurethane, water-based polyurethane, oil, orange shellac, etc. You’ll be able to tell how each stain looks with each ﬁnish. Label each one. Use both sides of each board, and you’ll have a wooden encyclopedia of stain and ﬁnish combinations. Plus: How to stain wood evenly.
I do not rip on the table saw as a rule, to prevent kick back that periodically occurs when natural wood pinches the blade, turning the wood into a missile. I bought a fairly powerful saw, so this is one place where a lighter saw would be adequate. Essentially, I use the table saw for ripping sheet goods, cutting dados, tenons, and cutting small parts to length – all of which can be done with a 1.5 HP saw. I ended up with a King 3 HP, three-belt drive, 10" table saw. The castings are true, and the King Tru-rip fence reminds me of the Biesmeyer fence used on the Canadian General saws. The model is KC-11FX, and it can be purchased for less than half of the price of other, similar saws. On this purchase, I went with the suggestion of Jeff at Brettwood Machinery – he was right; a very good value saw that runs smooth, and has a decent fence.
Let’s face it, one of the most significant costs of your shop will be its foundation. While you’re at it, what about adding space above your shop? There may be regulations preventing you from building living space above your shop if it is in an urban setting or in an outbuilding, but there may be some flexibility depending on where you live. It is in the municipality’s interests to encourage infill housing that uses existing infrastructure. At a minimum, think about including attic trusses to create some space above your shop for drying lumber or storing equipment. Access could be from simple pull-down attic stairs or from the exterior if you don’t want to lose floor space to a stair or ladder. If you’re creating an addition to your house, you may be able to add a couple of rooms you’ve always wanted, such as a family room, office or in-law suite.
If you live where summers get hot and humid, you may need more than a fan to keep cool in your workshop. Fortunately, air conditioners will both dehumidify and cool your space — and you don’t need a traditional window to get the job done. Instead of a residential window unit, consider a freestanding portable air conditioner that you can use as needed on hot days.
Depending on your situation, you may need to upgrade to 200 amp electrical service in order to meet the needs of your house and your shop. It may also be in your interests to add in a separate electrical service meter on your shop so that you can clearly write off electrical use for your business, or in future rent the space out and clearly separate out the utilities for billing your tenant. Generally, you don’t want to skimp on the power to your shop or on the lighting you include.
If your shop lacks wall space or doesn’t have a long enough wall to accommodate long stock, another option is to place the crosscut saw near an operable doorway with the right-hand side closest to the door (see option 2 in the illustration). This leaves most of the length of the fence to the left of the blade (preferable if you’re right-handed), allowing short and mid-sized parts to be cut to length or trimmed without having to open the door.