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Page 1: Workbench Magazine No. 287 - Woodworking … · 42 WORKBENCH FEBRUARY2005 People trying their hand at woodworking for the first time often have a lot of questions — and for good

42 W O R K B E N C H ■ F E B R U A R Y 2 0 0 5

People trying their hand at woodworking for the firsttime often have a lot of questions — and for goodreason. There’s a lot to learn. The first questions arealmost always the same:Which tools should I buy, andwhere should I set up shop?

Choosing tools might seem intimidating because ofthe many choices that exist.But, for the most part, toolsare easy to get your hands on.Manufacturers offer toolsfor most every task and budget. (We’ll talk about the specific tools you should have in the next issue.)

Shop space, on the other hand, is tougher to comeby.We all dream of having the perfect shop building —one that’s custom-made for woodworking and bigenough to hold every tool we want. But in the realworld, we usually have to carve out shop space some-where within the confines of the property we have.

For most of us, that means setting up shop in eitherthe basement or garage. The luckiest among us may

SUREFIRE STRATEGIES

FOR SETTINGUP SHOP

Here’s what youneed to know to setup a hard-working

workshop in any ofthree different areas

in your home.

FUNDAMENTAL SKILLS FOR

Page 2: Workbench Magazine No. 287 - Woodworking … · 42 WORKBENCH FEBRUARY2005 People trying their hand at woodworking for the first time often have a lot of questions — and for good

43W W W. W O R K B E N C H M A G A Z I N E . C O M

have an outbuilding, or at least the space to erect one,that can serve as a dedicated workshop.

Each of these spaces comes with its own advantages.And, to be honest, there are some compromises.At rightyou’ll find a quick overview of the pros and cons of each.In the next few pages, we’ll talk in detail about specificconsiderations you’ll face when setting up a shop in abasement, garage, or dedicated building.

Wherever it’s located, your shop has to be equippedwith some key necessities in order to function well forwoodworking.A list of those appears above.Chances arethat no prospective shop space will have all of theseuntil you make some upgrades.Even a dedicated buildingmay not offer everything you need, unless you’ve builtit specifically as a woodworking shop.And you’ll prob-ably have to buy or build some items designed for thecraft, like storage cabinets and a workbench. But that’shalf the fun of getting started in woodworking.

WORKSHOP NECESSITIESSPACE. Your shop has to hold all your tools and supplies

with floor space to spare for work areas. Think about headroom,too, because low ceilings and long boards don’t always get along. Ifyour shop lacks adequate space, consider whether areas nearbycould be annexed for storage or jobs like assembly and finishing.

WORKSURFACES. You can’t get much done without sturdyplaces to set your work. A traditional cabinetmaker’s bench might bethe ideal, but a basic folding workstation or solid-core door laid onsawhorses will work. Building a top for the table saw even makes it asuitable work surface, and a few clamps can “pinch hit” for a vise.

ACCESS. Shops have unique access needs. You have to getheavy, bulky tools in, as well as long boards and plywood sheets. Astraight route in and a large doorway simplify this. Don’t forget,either, that those projects you build will have to find their way out.

LIGHTING. Quality work requires good lighting. Fluorescentlamps provide economical shop lighting that doesn’t cast harshshadows. In specific work areas, add incandescent or halogen tasklighting. For safety’s sake, put lighting on its own circuit.

POWER. Woodworking tools use a lot of electricity. Bigrouters may draw as many as 18 amps, which will max out a 20-ampcircuit. Table saws can draw even more. If you have only one shopcircuit, you can’t run another tool, like a dust collector, at the sametime. You need at least two 20-amp circuits for outlets. Three isbetter. If your big tools (table saw, etc.) can be rewired to run on 220volts, do it. They’ll draw half the amps, leaving more power availableto drive other tools.

STORAGE. Shops quickly fill with stuff that takes over avail-able work space. And without enclosed storage, everything gets lostor covered with dust. Storage doesn’t have to be expensive. Use oldkitchen cabinets or shop-built versions. Lumber requires solid racksto keep it flat and avoid damage from moisture.

CLIMATE CONTROL. Heating and air conditioning maysound like luxuries, but without one or both, you’ll lose a lot ofpotential shop time. Plus, wide swings in temperature and humiditycause tools to rust and lumber to warp and crack. Cooling proveseasy, but heating requires more care to guard against explosivefumes and dust that may get to a pilot light.

VENTILATION. Shop air also needs to be clean. Airbornedust can ruin wet finishes, not to mention your lungs. And somecommon shop solvents give off dangerous fumes. Windows are theeasiest way to ventilate, or you can add an exhaust fan. Just makesure it has an explosion-proof motor.

DUST COLLECTION. The best way to create a clean shop isto capture dust at each tool, before it can escape to the floor or air.A shop vacuum works for some tools, but larger tools require a dustcollector. You can roll a small collector from tool to tool. Or, runducts to multiple tools and connect them to a central collector. Use acirculating air filter to get rid of tiny dust particles in the air.

SECURITY/SAFETY. A shop needs to offer a safe environ-ment for those who use it and the tools it contains. Cut off power totools if anyone besides yourself (kids especially) can get to them, andprotect your investment with sturdy locks and adequate insurance.

SHOP LOCATION PROS & CONS

PROS

convenient location, cli-mate control, good security,

easy access to electricity

easy access, convenientlocation, isolated, amplespace, storage options

can be customized, amplespace, storage options,

isolated

CONS

restricted access, noise anddust get into house, can bedamp, low headroom, dark

requires electrical upgrades,shared space, reduced secu-

rity, climate control issues

high cost, land availability, requires dedicated systems,

may be hard to access

BASEMENTSHOP

GARAGESHOP

DEDICATEDSHOP

Page 3: Workbench Magazine No. 287 - Woodworking … · 42 WORKBENCH FEBRUARY2005 People trying their hand at woodworking for the first time often have a lot of questions — and for good

FUNDAMENTAL SKILLS FOR

44 W O R K B E N C H ■ F E B R U A R Y 2 0 0 5

BASEMENT SHOPSome basements get finished and used as living space,but many are left unfinished and underutilized. If yoursfits the latter description, it’s filled with untapped poten-tial. So why not turn at least some of it into a shop? Afterall, a basement comes already equipped with two of themost important — and most costly — necessities: climatecontrol and electrical access. But a basement shop doespose a few unique challenges.

DCramped Quarters. Storageof household stuff eats basementspace, as do “mechanicals,” such asthe furnace and water heater. Plusceiling heights are often 8' or shorter,which complicates material handling.

CPlenty of Power. Most base-ments don’t have enough outlets. Butyou can add them by tapping intoyour home’s existing service panel. Ifno extra space exists in the panel, runa sub-panel to the workshop area.

CHigh Security. Few locationsare more secure than a basement.The tools inside won’t be seen byoutsiders unless you invite them in.

DAwkward Access. Gettingtools and materials into and out of abasement shop is tough. Stairs areoften steep with low clearance over-head. And they may be located wellinside the home, meaning you haveto negotiate corners just to get there.Walkout basements offer great accessbut may require you to trek throughthe yard to get to the shop.

DLow Airflow. Because mostbasements have small windows, youshould add an exhaust fan for effec-tive ventilation. This is of primaryimportance in a basement, as dustand fumes can invade the rest of thehome and pose a health risk.

CComfortable Environment.Most basements already have climate control from the home’s existingsystem. To prevent dust and fumesproduced in the shop from gettinginto the rest of the house, add fil-ters to air-return vents in the shop.

DKeeping Warm AND Safe.Dust and fumes that get into thehouse are annoying, but if theyreach a furnace burner, they can bedeadly. Don’t build a shop in thefurnace room unless the furnace isa“separated combustion” modelthat draws combustion air fromoutdoors. You may be able toenclose a standard furnace.

A dust collector can keep chips anddust under control,but there’s still nodevice that will suck up shop noise.Table saws, thickness planers, andshop vacuums often put out 80 ormore decibels (dB) of sound.

This is a big problem in a base-ment shop because those noisesinvade living areas. Stopping themrequires special measures.

To keep sound from escaping,install sound-deadening insulationin joist and stud bays.Then pad thestuds or floor joists, or hang the dry-wall on metal “resilient channel” (seethe Illustration at left).These methods isolate the drywall to stop vibrationsfrom transferring through the wall.

To further deaden sound, add asecond layer of wall material. Thisadds mass,which reduces vibration.

LOCK IN NOISE

{ Sound travels through walls as vibrations that can turn surfaces into giantloudspeakers. Layers and mass stop these vibrations from escaping.

Photo: Basementshop scene

GO ONLINE FOR:•More strategiesfor noise control •Downloadable

Garage-ShopProjects & Ideas

Fill studbays with

soundblanket

insulation

SoundBlanket

Insulation

Double layer ofdrywall reducessound transferthrough ceiling

ResilientChannel

Attachdrywall

to channelwith 1"

screws sothey don'tpenetrate

studs

Second wall layerof T1-11 plywood deadenssound and provides solid

surface for hanging objects

Page 4: Workbench Magazine No. 287 - Woodworking … · 42 WORKBENCH FEBRUARY2005 People trying their hand at woodworking for the first time often have a lot of questions — and for good

45W W W. W O R K B E N C H M A G A Z I N E . C O M

CWide Open Spaces. Garages have loads of openarea, and many feature ceiling heights of 9' or more. Ofcourse, tools have to share the space with cars, but youcan make even big tools portable by following the advicein the Sidebar at right.

CEasy Access. The overhead door makes access easybecause you can back your load up to (or into) the shop.Add a passage door so you can get in and out easily, too.

CVast Ventilation. Once again, a large door provesits worth by allowing unlimited ventilation. Since you maynot want the door open at times, though, add windows.

DFull View. An overhead does compromise securityby showing all of your tools to every passerby wheneveryou open the door, especially if your garage sits close tothe street. Protect your shop with sturdy locks and blinds.

CAccess To Power. Many attached garages housethe electric service panel for the home, so you can tap intoit to add shop circuits. If your service panel is full, locatedelsewhere, or the garage is detached, then run a feed lineto the garage, and install a sub-panel to power the shop.

DFew Outlets. Garages (detached especially) haveminimal electric capacity. You’ll have to run wires from theservice panel to power outlets and tools. Be sure to useheavy-gauge wire and high-quality 20-amp receptacles.

CAdd Lighting Easily. Most garages are lit with justa bare bulb or two, but you can easily swap those fixturesfor fluorescent units that will fully light the space. In coolerclimates, make sure to get fixtures with electronic ballaststhat will still work at low temperatures.

DControl the Climate. Even an attached garagemay not be heated or cooled. A window air conditionermakes cooling easy, but heating requires more care. Forsafety, any gas heater in the shop should have separatedcombustion.Or use an electric unit. See the Sidebar onpage 46 for more information about shop heating.

GARAGE SHOPIn most homes, you won’t find a better spot for settingup a woodworking shop than the garage.The garage’spotential comes from its loads of open space and isola-tion from living quarters.Garages also have plenty of wallspace on which you can build storage and worksur-faces. Because the garage is a multi-use space, you willlikely have to build in storage space for non-shop itemsand make tools mobile in order to park cars inside.

{ You can have a fully functional shop and garage in one building. Make toolsand shop fixtures mobile, then designate “parking” space for each one.

When woodworking tools move into a garage, cars, yard equipment,and bikes often get evicted.Or those items take over and bury the tools.

But putting a woodworking shop in the garage doesn’t mean youhave to clear everything else out. I’ve had a garage shop for years thatfunctions very well and still allows space for all the other stuff. No, Idon’t have a huge building. I simply have wheels under many of mytools, as shown in the Illustration.

With these wheels, I can “park” tools around the perimeter of thegarage, and roll them into place when needed. I take over both stallsfor elaborate projects,or use just one and keep my wife’s car in the other.

How you mobilize is up to you.Commercial mobile bases are avail-able either custom-sized for particular tools or in “universal” stylesthat you customize.You can fit a mobile base to a workbench or otherhard-to-move shop fixtures, though you may have to modify the base.

Shop-built mobile bases present another great option.Designing yourown bases lets you customize them to meet your needs.When possible,build in storage to keep related tools and accessories together.

MOBILITY BRINGS VERSATILITY

Parkingspace foreach tool

Bench toolstorage

Mobile Basesfor stationary tools

& workbenches

Allow clearancefor vehicles

Build storage into openarea below table saw

Page 5: Workbench Magazine No. 287 - Woodworking … · 42 WORKBENCH FEBRUARY2005 People trying their hand at woodworking for the first time often have a lot of questions — and for good

FUNDAMENTAL SKILLS FOR

46 W O R K B E N C H ■ F E B R U A R Y 2 0 0 5

DEDICATED SHOP Every woodworker dreams of having a stand-alone shopbuilding where he can work on projects without inter-ference. If you’re lucky enough to have an extra buildinglying around, or if your property offers space for one,you can build a shop with fewer compromises than onelocated in the basement or garage.Building a dedicatedshop takes a larger investment, though,because it requiresdedicated systems and more construction or finish work.

CSingle-Use Space. A dedi-cated shop offers more than space —it allows you to position your tools forefficient work flow, and leave themand your projects undisturbed.

CStorage Options Abound. Ihaven’t talked much about storage,simply because you’ll have to build itin wherever your shop is located. Buta dedicated shop allows the mostfreedom for building in storage.

CControlled Access. Dedicatedshops accept overhead and passagedoors, giving you many access options.The site will dictate whether you canreach the building with a vehicle.

DSort Out Security. It’s tougherto monitor a shop that’s not locatedin or next to your house. So installstrong doors and windows secured bygood locks. An inexpensive alarmsystem adds peace of mind.

CMake It Bright. Install win-dows to allow natural light in yourshop. Then add fluorescent overheadlights and incandescent task lights.Put lights on their own circuit, so theywon’t shut off if a tool trips a breaker.

DClimate Control Adds Cost.A dedicated building requires its ownheating and cooling systems, whichincrease construction costs. Cooling a

shop is easy — just use a window air conditioner. Heating gets moreinvolved, but a variety of systems existthat work very well in a shop environ-ment (see the Sidebar below).Be sureto seal all gaps, insulate, and installvapor barriers to make the climatecontrol system efficient.

CDucts Control Dust. Locatingtools “permanently” makes dust col-lection more efficient. That’s becauseyou can run rigid duct to tools andrely less on suction-robbing flexiblehose. Plan for dust collection as youplan your shop layout to ensure ade-quate capacity and ducting withouttoo many twists and turns.

Winter has long been designated “woodworking season.”So you’ll need a heating system if you don’t live in awarm climate.A space heater may be adequate, or youmay have to install a more powerful system.

I’ve known many woodworkers who heated theirshop with a wood-burning stove, often stoked withscrap wood and “mistakes.”But you have to tend the firewhile using the shop and are left with no heat at all whenthe shop isn’t in use. Plus, you usually have to increaseinsurance coverage if you have a wood-burning stove.

Thankfully, gas and electric heating systems well-suited to workshops are commonly available.Both typescome with compromises.

A gas system requires that you run lines or install apropane tank.This increases construction costs.But gasheat is efficient and usually cheaper than electric.Electricheaters cost more to run, but cost less to install.Note:220-volt heaters are more efficient than 110-volt units.

Whichever system you choose, add a thermostat, soyou can heat the shop just enough to keep the interiorabove freezing when the shop isn’t in use.

WHAT’S COOL IN HEATING

{ In-floor hydronic heating systems provide great shopheat, but have to be built in. The others retrofit easily.

Direct-vent,separated-combustion

gas heater hangsfrom ceiling and heats

with forced air

Wall-mounted electricfurnace heats with

forced air

In-floor hydronic systemwarms floor slab to produce

radiant heat

Some modelsdraw air andexhaust waste

through a singlewall opening

GO ONLINE FOR:•More waysto heat yourshop safely

and efficiently