Between 265 & 485 SQ/FT 1950s Craftsman Garage retro remodel

Okay, here is my latest way-too-late update.

I got the corner drawer for the shelving built. Since the baby could come any time, I want to try and knock out as many bigger things as I can, and then save some of the other stuff that I can do in 10-30min spurts for when the little guy arrives.

I'm glad I got this one out of the way. It took me about 3 frickin hours and definitely had some moments of frustration. All that to say, its built, and soon it will be ready for screws, bondo, and paint. Here is how I did it:

Here is what I'm starting with. The goal: get an open-able drawer on the end of the curved shelving:


By daveamy at 2011-06-18

So, first things first - Make curved sections that match the curve of the wood already up on the wall. I didn't want to have to do a lot of bondo repair to blend the curve, so I wanted to get as close as possible. I had to match each curve because, of course, they were slightly different (would come back to bite me in the ****). In any case, I made two of these:


By daveamy at 2011-06-25

And one of these:


By daveamy at 2011-06-25

And did a little bit of this:

By daveamy at 2011-06-25

And put them together like this (doing it right took about 1.5 hours):

By daveamy at 2011-06-25

What the above picture doesn't show is the tendency of the plywood facing to pull out the screws attaching the corner pieces. I had to get that sucker strengthened up. Hence, more wood and glue:

By daveamy at 2011-06-25

By daveamy at 2011-06-25

There is not a screw in the top of the post securing it down for a reason. I found that depending on how I tweak where the top of that post meets the top plywood piece, is changes the caddy-corner curvature of the whole piece. I will wait to 'fine tune' it to get a perfect fit before setting a screw in there.

Here is the general idea:

By daveamy at 2011-06-25

Hinges will be located on the left side and it will open from the right side. I'll put a little wooden knob on it and it will stay in place with some little magnets I'll counter sink in each piece. Then both will get bondo and matched up perfectly. They are already close, closer that what that picture shows. I had to tweak the curved facing on the bottom that was already up there. It was a huge pain, but will hopefully all pay off, one day

Also, I needed to blow off some steam later, so I decided to put that energy to good use and finish painting some garage door hardware:


By daveamy at 2011-06-25

By daveamy at 2011-06-25

Here is where things currently stand:

By daveamy at 2011-06-25

really cool. those shelfs are going to be really unique. Thanks for all the construction how tos.

Nicely done!

All right who's pregnate here, you or the wife? Looks like nesting to me
good job on the wood work!

BUGTHUG said:

All right who's pregnate here, you or the wife? Looks like nesting to me
good job on the wood work!

Click to expand...

lol...heck yes! Since we're having a son, it's only fitting that the garage would be the 'nest' - I'm just getting it ready so that when he gets old enough he can start having fun and messing around in there

Those cabinets are gonna be stupendous (only word I could think of because I'm sick of awesome so I didn't want to say AWESOME). And thanks a lot because now I have to paint MY garage door hardware.

Ow man! Very nice work! Wonder how you will finish your work bench...
Very nice tools!

Very nice a true labor of love .

Okay, BIG update - lots of pictures.

So it was time to knock out some more work on these shelves. I wanted to get the center section up and rocking. Here is how it happened.

First, I took some measurements, then cut some 2x4 to make the main support beams going up:

By daveamy at 2011-06-26

Here it what looked like from the bottom shelf:

By daveamy at 2011-06-26

Now, I had to find a way to attach them up at the top, otherwise they would just dangle, so I had another 2x4 come out and keep it company

By daveamy at 2011-06-26

I screwed those two together, and left everything loose so I could check level about 40 times. I didn't worry about the bit stick up at the top, since eventually that will be covered by insulation and ceiling.

By daveamy at 2011-06-26


By daveamy at 2011-06-26


By daveamy at 2011-06-26
One up, another one to go!

By daveamy at 2011-06-26

Once I had those up, I wanted to work on the shelves that will go on the main section.
First, I start out with a piece of plywood:

By daveamy at 2011-06-26

Took some measurements and drilled the starter holes where the 2x4s will fit through:

By daveamy at 2011-06-26

Holes, sawed out:

By daveamy at 2011-06-26
Time to make a curve:

By daveamy at 2011-06-26

Curve made (and later cleaned up on the belt sander):

By daveamy at 2011-06-26

This picture inaccurately reflects the time spent trying to get those things on. Look there, its easy!

By daveamy at 2011-06-26

I wanted to attached the shelf backs to the wall, so I used some scrap lumber I had and fit it before I put them on (actually, that's not true. I put it on, then this came to me, and I took it all back off again. So much for that )

By daveamy at 2011-06-26

I leveled the front of the shelves and then used these little guys to hold up the front, then locked everything together with glue:

By daveamy at 2011-06-26

Next project: make the center shelf end pieces.


It starts with a piece of plywood. They have a half circle design. When I first had to do this on the curved shelf tops, I searched around for something circular that was the size I was looking for. Like that was going to happen haha. So, I figured out a system:

Measure the space the curve takes up, then divide by two:

By daveamy at 2011-06-26

By daveamy at 2011-06-26

Then, cut a piece that big, put little notches in it:

By daveamy at 2011-06-26

...and make your 'custom made' circle!

By daveamy at 2011-06-26

By daveamy at 2011-06-26

...or go buy a $2 drafting compass, haha. (its amazing what you think of after the fact)


By daveamy at 2011-06-26

I put a little rough radius on it on the spindle sander, then checked the fit (checking the fit and adding shims was a 20 min process). The better the fit, the less bondo I'll have to use, the less sanding I'll have to do, the less I'll feel like I'm doing drywall joint compound all over again: better to spend the 5 min making a shim.

By daveamy at 2011-06-26

Check it out!

By daveamy at 2011-06-26

From a distance:

By daveamy at 2011-06-26

By daveamy at 2011-06-26

Here is how things are looking now! It's starting to shape up!!!

By daveamy at 2011-06-26

By daveamy at 2011-06-26

By daveamy at 2011-06-26

By daveamy at 2011-06-26

Here is the concept art just as a reference:

By daveamy at 2011-06-10

Lookin' closer and closer!!!!!!!!!!!

i just went through 5 pages looking for that drawing , i come back to the last page and you posted it

So just as a fun post, some of you may be asking, how the heck is he getting all that stuff together. Okay probably not haha, but I figure with all the hard work they've been doing, I'd highlight the workhorse tools that have been shouldering much of the burden.

1. Radial saw


By daveamy at 2011-06-26
While it has already been featured in this thread (2nd post), can you really get enough of this bad boy? This sucker has been eating 2x4s for lunch, as it has done for 60 years. Yes, 60 years.

2. Table saw


By daveamy at 2011-06-26
This is where I spent most of my time - what a versatile machine. Whether I am ripping, or doing fine crosscutting, this one does it all. While not cutting, the table frequently accumulates a bunch of junk I'm working on. Probably for every hour I've spent cutting, I've spent moving stuff back and forth on it and off it. Its been fun.

3. Table saw router extension


By daveamy at 2011-06-26
While it doesn't get used as frequently as the 2 above, this little setup has been a LIFESAVER with making/doing trim and putting a radius on everything but the kitchen sink. Love it.


4. Ridgid Oscillating belt sander


By daveamy at 2011-06-26
Yes, its true, in the 1950s garage, there will be a Ridgid belt sander. Trust me, it has EARNED its place. This, and the miter saw, are the two amazing power tools that the 50's couldn't bring us. It it weren't for this guy, there would be mismatched trim, gaps in everything, wrong angles, and uneven surfaces. It makes the custom fit truly 'custom', meaning that when you realize that they built the wall at 94 degrees instead of 90, just stick your stuff on this thing for a few seconds until you can jimmy rig it enough to look right. Its funny, because its almost wrong...sanding stuff to make WRONG angles. It's almost even like a moral dilemma. But its then that you realize its ohh so right


5. Jig Saw


By daveamy at 2011-06-26
An $8 2nd hand store find, this thing is old and has about a 1/4 inch play in the reciprocating mechanism (no joke), but it takes the wood in its teeth, calls it some dirty names, and shows it whose boss. This has made quick work of anything curved. I really enjoy it also for the scroller feature where you can turn the blade independent of the saw angle.

And finally, we have the MVP of the shop:







By daveamy at 2011-06-26
Yep, a Ryobi cordless drill. I would be lost without it. Its been used on everything. Its taken spills, its been left on every flat surface in the entire garage (and some not flat) and when I can't find something even when its right in front of my face, I probably get the most pissed when I can't find this It has battled countless screw heads and wood holes.

Its interesting that pretty much 2 of the tools I'm most grateful for are just the modern stuff. But you know, thats okay. You can get it done with style (radial saw), but the most important thing is that it gets done, right? These wonderful tools have helped to make all this possible. I'm probably going to pick up a miter saw at some point for its absolute convenience, but in keeping with the flavor of the garage and my buying habits with this garage, I'd like to find a slightly older, made in USA one.

Thanks all for following along in this fun adventure! I hope you are enjoying it!

Brunow said:

Ow man! Very nice work! Wonder how you will finish your work bench...
Very nice tools!

Click to expand...

I have resigned myself to the fact that the workbench is going to come after the baby is born - there is just no way to get it done beforehand. I've been so focused on the shelving that my mind hasn't had too much vision yet for the workbench, but I do know a few things, some design parameters, perhaps:

1. It will have the drill press on it
2. It will have a grinder on it
3. It will have countersunk magnetic parts trays in it
4. It will have flip top storage built into the top
5. I'd like to find a way to put a wood vise on it
6. I was thinking about a mini fridge or a computer tray in it, but am undecided on those things yet.

I dunno guys, what are some typical workbench 'essentials'? What should I incorporate, vintage or not?

I'd be more than happy to hear all of your ideas!

tinbender 66 said:

Those cabinets are gonna be stupendous (only word I could think of because I'm sick of awesome so I didn't want to say AWESOME). And thanks a lot because now I have to paint MY garage door hardware.

Click to expand...

Thanks Tinbender. It has quickly spiraled out of control

I think up next will be the actual inside of the garage door - I have to paint that hardware, and I'd like to get it matching the walls as well.

***** to be a perfectionist

OK, you asked for ideas.

Woodworking vise can be a pattern maker's with wood jaws. Then mount your mechanic's vise on a suitable board and mount it in the woodworking vice. But I don't like that idea. I like mine separate as I pound the snot out of things in the mechanic's vise and not so much the wood working vise.

I do not like storage in/under a bench top as once the project starts it is now a pain to access. My beautiful new Masterforce tool-chest-combo has one of those kickout tables that is useless cause once you put stuff on it the bottom's drawers are not accessable.

I don't like stuff on the workbench. Eg, I prefer stand alone drill press, grinder... Only a vise on the bench top. That space os for projects only.

At least in my perfect world. Which we all know I'll never see.

BTW, I love your shelf design. Man was meant to appreciate curves!

Dave.

This may be a little bit late but if you want to duplicate the curves more closely you can buy a router bit with a bearing on the end. I believe they are called "pattern bits". I've used this countless times to create new table saw inserts and wooden swords for the kid to use in a play. The bit fits into my hand held router (mounted upside down in a table to emulate a router table). Then I attach the pattern to the blank and just run it around the bit. Presto. I have a new piece that is almost identical to the pattern.

mdbeck1 said:

This may be a little bit late but if you want to duplicate the curves more closely you can buy a router bit with a bearing on the end. I believe they are called "pattern bits". I've used this countless times to create new table saw inserts and wooden swords for the kid to use in a play. The bit fits into my hand held router (mounted upside down in a table to emulate a router table). Then I attach the pattern to the blank and just run it around the bit. Presto. I have a new piece that is almost identical to the pattern.

Click to expand...

Yes, those bits are great. I plan on having a wide assortment of them to do pattern making with guitar construction. However, right now the garage budget does not allow such luxuries Otherwise I'd be all over it!

onewaydave said:

OK, you asked for ideas.

Woodworking vise can be a pattern maker's with wood jaws. Then mount your mechanic's vise on a suitable board and mount it in the woodworking vice. But I don't like that idea. I like mine separate as I pound the snot out of things in the mechanic's vise and not so much the wood working vise.

I do not like storage in/under a bench top as once the project starts it is now a pain to access. My beautiful new Masterforce tool-chest-combo has one of those kickout tables that is useless cause once you put stuff on it the bottom's drawers are not accessable.

I don't like stuff on the workbench. Eg, I prefer stand alone drill press, grinder... Only a vise on the bench top. That space os for projects only.

At least in my perfect world. Which we all know I'll never see.

BTW, I love your shelf design. Man was meant to appreciate curves!

Dave.

Click to expand...

Thanks for your input. Since I don't have a ton of room, I'm having to consolidate. Either that, or already planning to include an independent floor standing drill press affords me the excuse to have one on the table

I have been thinking about having some curves on the workbench instead of just a rectangular top - it would flow really well with the rest of the garage, but it would be harder to do and I'm not sure if it would hamper functionality. Thoughts?

So here's what I've been doing for the past two days.

From this:

By daveamy at 2011-06-27




To this:

By daveamy at 2011-06-30

By daveamy at 2011-06-30

It has been a fun (and interesting at times) experience. I say 'two days' because day one was me putting the whole thing together wrong - when I finished it, plugged it in and flipped the switch, it was spinning up, not down. I feel that it was good 'training' for when the other grinder comes my way. I like the color scheme and so I think I'll stick with it.

The dust shields are not on there yet because they need a little bit more attention (aka repair). While I painted all the parts while separated, I think I'm going to mask off some stuff and shoot the green again - its a little thin in some areas, and I want to take out the rods and nuts holding the whole shebang together and recoat around the nut slots since the paint got a little tore up there (can't really tell in the pictures) and then get some washers to keep the nuts from ripping on the paint.

More (better) photos will be added later once the dust shields are completed and installed. I hope its not cheating that it really is a 1940s grinder in the 1950s Craftsman Garage, but hey, I've got that early 50s one coming at some point, so hopefully the balance in the universe will be maintained

Looks like you've been in Jack's paint supply!

That grinder looks bitchin'

Love this build. good job!

Red Leader said:

Yes, those bits are great. I plan on having a wide assortment of them to do pattern making with guitar construction. However, right now the garage budget does not allow such luxuries Otherwise I'd be all over it!

Click to expand...

It seems to me I paid about $20-$30 for the last one that I found. You can order them from http://www.woodcraft.com/Family/2008072/WHITESIDE-FlushTrim-Two-Flute-Bits.aspx. It will make your life a WHOLE lot easier.


...also if your router will handle the 1/2" collets use those. They won't deflect as much.

Tinbender - thanks, and really thanks for your kind words throughout this whole thread!

santagary said:

Looks like you've been in Jack's paint supply!

Click to expand...

Haha, maybe I did!

rican240sx said:

Love this build. good job!

Click to expand...

Thanks! It has been very enjoyable and therapeutic for me! Lotsa fun

mdbeck1 said:

It seems to me I paid about $20-$30 for the last one that I found. You can order them from http://www.woodcraft.com/Family/2008072/WHITESIDE-FlushTrim-Two-Flute-Bits.aspx. It will make your life a WHOLE lot easier.


...also if your router will handle the 1/2" collets use those. They won't deflect as much.

Click to expand...

mdbeck,

I totally agree with you. One of those would be so awesome to have. My challenge is that there are a lot of probably $20-50 items that would make nearly every job easier, but then my budget (currently) would be blown. If I came into some money just to buy some added accessories, I think at the top of that list would be a magnetic featherboard for the table saw. It would have come in handy many, many times and I know would be safer. As it is now, I just have to say a prayer and stay alert

I think what I've learned is that I have been able to slowly acquire useful tools one piece at a time and they have built on each other to the point where it has been really great being able to just 'have' what I need for the build about 80% of the time. I'm getting there!

As always, I really appreciate your suggestions!

very nice build, i'm in............

Didn't you know that it is against forum rules to post pictures of such awesome machinery? I'm going to have to confiscate those young man!!

Red Leader said:

mdbeck,

I totally agree with you. One of those would be so awesome to have. My challenge is that there are a lot of probably $20-50 items that would make nearly every job easier, but then my budget (currently) would be blown. If I came into some money just to buy some added accessories, I think at the top of that list would be a magnetic featherboard for the table saw. It would have come in handy many, many times and I know would be safer. As it is now, I just have to say a prayer and stay alert

I think what I've learned is that I have been able to slowly acquire useful tools one piece at a time and they have built on each other to the point where it has been really great being able to just 'have' what I need for the build about 80% of the time. I'm getting there!

As always, I really appreciate your suggestions!

Click to expand...

I just wanted to make sure that you knew you could get these fairly inexpensively. BTW: Watch garage and estate sales for woodworking tools. They're usually REAL cheap

The wife has finally figured out that I save us a lot of money on repairs. so we've got a deal. I can buy most of the tools that I want as long as I don't go over about $100/week. However I need to have a CURRENT project that is in need of that tool. If I need to go over the $100/week I need to discuss it with her to ensure that we don't overdraw the bank account.

Case in point: For Father's day/birthday she bought me a compressor (5 HP-80 gallon) and had to "authorize" money for a regulator and dryer. The air distribution system (black pipe) will have to get started soon.


A note from a longer term father.... Make SURE she knows how much money those tools save her on repairs. ..and MAKE D&MN SURE that she understands that's money back into the bank account to spend on other things. ...including tools.

Guys,

Thanks for all the wisdom and advice! It is much appreciated and much needed.


So quick update - yesterday I stopped by the hab outlet and found some lighting! I honestly didn't think I'd get to any lighting ANY time soon but it was such a good deal. Got some small fluorescents, a couple of puck lights and another small incandescent light.

Also work done (but not shown) was re-routing some electrical stuff so that one of the light switches at the front of the garage will control the entire lighting of the cabinets (fluorescents, incans, and future rope lighting) - I also found a 15amp double breaker and installed a circuit just for the lighting and wired it up. We tested it and everything works! Also, each of the small fluorescents and the incandescent have their own independent on/off switch, so that will also provide lots of options. I plan to run romex between each light under the cabinet - does anyone know if code specifies that I HAVE to cover it with a metal hose or anything? It won't really be 'exposed' for anyone to see, but just like covering all my bases.

Okay, enough talk! Here are some pictures. The outside cases are getting the flat black treatment to match the underside of the cabinet. I had a kid that I've been mentoring for 4 years come over and give me a hand (he suggested it as he loves this stuff):


By daveamy at 2011-07-02

By daveamy at 2011-07-02

Before:

By daveamy at 2011-07-02

After:

By daveamy at 2011-07-02

I got 3 of the small fluorescents, but they had 2 more left and for the price I think I will try and go back and pick them up if they have them.

I will also REALLY, REALLY try to get the bondo on the cabinets today because that needs to get done and that is the last step before painting!!!!!!!!!

See ya again soon

I like the cabinets a lot can,t to see them painted

Great thread!

Are you painting the shelving? Just wondering if you have ever tried MDF for paintable projects. Cuts, routers and paints like a dream.

Man, I'd love to find an old Unisaw like that!

sneakyfast said:

Didn't you know that it is against forum rules to post pictures of such awesome machinery? I'm going to have to confiscate those young man!!

Click to expand...

Heheh.

Or better yet, find someone to help relieve them of that "old rusty stuff that's on its way to the junkyard..."

You'd be AMAZED at what people throw away, simply because it has a layer of rust (that can be cleaned off in a few hours) and old bearings (that can be replaced in an afternoon for under $20-$30).

AMAZED.

Snowbound said:

Great thread!

Are you painting the shelving? Just wondering if you have ever tried MDF for paintable projects. Cuts, routers and paints like a dream.

Man, I'd love to find an old Unisaw like that!

Click to expand...

MDF is amazing. I know of its capabilities, although not personally.

Everyone and their mother needs to see this thread:

http://owwm.org/viewtopic.php?f=1&t=35139&p=235782&hilit=MDF+bondo#p235782

AND this thread:

http://owwm.org/viewtopic.php?f=1&t=87148&hilit=MDF+rick

After seeing these, all I can think of is...I am not worthy

There are some very talented people in this world. Those folks are some of them

Red Leader,

As another user of vintage tools. I have to ask. How do you deal with dust control? One of the reasons I rarely use my 6x48 Craftsman belt sander is the sheer amount of dust it sprays everywhere. I've done a number of reversable mods to my equipment.

Everything looks great. Amazing progress.
I like the mentoring. That's a great thing to do. So many kids want everything to be done for them rather than learning how to do it themselves.

BTW. I may have missed this. When's your son due?

Happy Fourth!

Best,
Leonard

Okay, new update!

Actually, I'll start it off with a fun picture.

My wife and I had a little brunch date in downtown Golden, and out of the corner of my eye I saw this:


By daveamy at 2011-07-02

By daveamy at 2011-07-02

There is just something about that that screams 'old auto shop!!!'

There was another guy looking at it and I asked him if he knew anything about it. He said he was surprised and happy to see them doing work on it, as he had previously been familiar with it as an old, dilapidated building. So, there is a good chance it might have been an old auto garage - I might try and do some history digging on it.
It looks like they might be turning it into a restaurant.

Okay, onto the updates.

I finally got the bondo up! Check it out:

before:

By daveamy at 2011-07-02

after:

By daveamy at 2011-07-02

By daveamy at 2011-07-02
By daveamy at 2011-07-02

What I learned about bondo: It sets up SUPER ULTRA FAST. Meaning, you mix it as fast as you can (10 second) and you start putting it on right away. Now I know why they say to mix only what you need that moment. I mixed it on cardboard, which, typically, is considered a no-no, but since this is going on plywood cabinets and not a concours show car, I think I'm okay.

I'll have to do maybe one or two more layers near the door opening at the end of the shelving unit, but I'm not in any hurry (or so I say haha) so I'll let it fully dry, then sand, then apply more as needed.

I will now paint the rest of the fluorescent lights and work on some electrical while that is drying and get another update in later this evening. Hopefully by the end of today I'll have a post with some working cabinet lighting!!!!!!!!! Whoohoo!!!

Red Leader said:

MDF is amazing. I know of its capabilities, although not personally.

Everyone and their mother needs to see this thread:

http://owwm.org/viewtopic.php?f=1&t=35139&p=235782&hilit=MDF+bondo#p235782

AND this thread:

http://owwm.org/viewtopic.php?f=1&t=87148&hilit=MDF+rick

After seeing these, all I can think of is...I am not worthy

There are some very talented people in this world. Those folks are some of them

Click to expand...

Thank you for the link those guys are very good . On the mdf it is great stuff I did some kitchen cabinets in one of my apartments and sprayed them with conversion varnish very happy with results.

cobraace said:

Thank you for the link those guys are very good . On the mdf it is great stuff I did some kitchen cabinets in one of my apartments and sprayed them with conversion varnish very happy with results.

Click to expand...

Those cabinets look awesome. Great work! Btw what is conversion varnish?

Red Leader said:

Those cabinets look awesome. Great work! Btw what is conversion varnish?

Click to expand...

It,s a professional grade 2 part finish for furniture or cabinets just like an auto grade paint very forgiving, easy to work with toxic as hell respirator a must.

I just made the door,s the rest is 1960,s plywood cabinets with a lot of bondo and sanding but look,s good