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Australian workshop - big plans in a small space

sams

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S.E Victoria, Australia!
This is my project of putting my workshop together. Unfortunetly I have to store things in it and use it while setting things up so it's slow going.

My aim is to have a very efficient layout that uses the limited space I have.

An example is one of my benches:

eqp-bench-03.jpg

eqp-bench-02.jpg

eqp-bench-01.jpg


This bench houses various tools in the draws, has my cut-off saw under the edge with it's own power outlet, tubs on the right and did have a single grinder and an arbor press on the top, however it now has a second larger grinder with a linishing attachment instead of the press.

The draws have heavy duty full extension ball bearing slides, they are only 300mm (1') deep though as the whole bench could not take up much space. There are also a lot of smaller features not mentioned like the cut-out behind the sheer cutter for larger strips.

This whole bench was made with a $90 arc welder using only the lowest quality electrodes!



Here's another bench I have in another corner:

l-asb-bench04.jpg

l-asb-bench05.jpg



At this stage it wasn't finished and now has a light fitting directly above the bench, a stero mounted just under the cleaing and the power cabling/conduit finished off. In the future I will the bottles and cans stored elsewhere so I will divide this large draw in half for other uses.

The containers are 24 compartment designs of which I have 39. They are used mostly for fastner storage. There is a step near the bottom to reach the upper containers and a large gap at the very bottom so I can slide my jack in every time.


Now equipment-

My vintage (1950's) but upgraded metal lathe:

hercus08.jpg


I also have another 4 year old lathe that's much larger for which I do my thread cutting and bulk work but it isn't as accurate ironicly enough.


I have this monster dual J-head Bridgport Synchro-trace mill, but I am going to get rid of it, it's pictured below without the heads bolted up:

mill01.jpg





My workshop also sports a decent home-brew sound system, I have 4 of these in the corners:

speaker1.jpg


I assembled these in their tuned enclosure myself which are powered off a JVC amp getting it's signal off an old laptop.


As I slowly get things together I am making bits that help, some will stay after I finish my workshop and some won't and example of the later is this shelf and all the engines below as all of these will be gone.

shelf1.jpg


This is 600mm (2') square which was shaped that way so I could get a standard sized board and chop it into 6 pieces to use as shelfs. It will be moved to my shed once it's built but in the meantime it helps me keep junk off the floor. It is made from 20mm (3/4") x 1.6mm (0.063") angle and uses ply for the shelves. I know that will never have to worry about it breaking under any weight I put on it.

Another small thing is this which I planned out and made by hand:

tap-stand.jpg


At the time I needed to source the missing bits but it's complete now, I will later make many others for the other odd threads I have.

I have many other things which I can take pictures of however what I have is only a fraction of what I have planned but can't do yet untill my shed is up and all this junk is out of my workshop.

Comments and questions welcome
 
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HSpencer

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Re: My unfinished garage in Vic/Australia

Very impressed with your machine tool set up, as well as the organization of the rest of your shop. I will be very interested to see the complete set up when you get it all done. I was extremely impressed with your bench cabinet drawers, as well as the small parts storage!! I am finding this one of the best set ups I have seen on the forum!! Please continue to post more pictures.
 
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sams

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Re: My unfinished garage in Vic/Australia

thanks for the support and kind words.

Looking for bolts has always been something that I found highly irritating and considered a waste of time, it took me a long time of searching till till I found these containers which happened to be $5 each. Here is a an example of how inside my M6 box when I was starting out:

l-asb-bench03.jpg


Comicly enough my fastner collection has grown that I am going to make another one of these for the other things it stores like fuses, nails, lugs, etc..

It is really frustrating to not be able to do more work to my workshop due to it being a temporary storage, however my shed should be going up starting as of about a month so hopefully I will start to have some real progress by then.

In the meantime I have a smaller junker mill coming that I am in the middle of putting a 3 axis DRO on.

I will see if I can get some pictures of my finished bench and perhaps of my excessive wiring system (2 x 30amp 240V circuits).
 
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sams

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Re: My unfinished garage in Vic/Australia

took a picture of my finished bench:

l-asb-bench06.jpg


Now a few things to note-

Jack on bottom left- this is made to slide in at the very bottom, I still need to make something that holds the handle straight up though, the rag is always there so the jack handle doesn't rest against my car pannels when I use it.

Draw hidden in kick pannel at very bottom- I didn't even want to waste the space in the kick pannel so I made a draw for the whole length of it.

Light fittings- this area has it's own light circuit with 3 lights. The light switch is in the corner.

Power- All my power for outlets and lights is in conduits. In the left hand outlet in the picture there is a switch in the middle of it, this then has a conduit go up out of the top to a single outlet. This switch turns my amp on. This saves me going up there to manually turn it off should I want that.

Stereo up the very top- As mentioned above it has it's power remotely turned on and sit's nice on it's own shelf. The small speaker on the to left is connected to the center channel to stop a dead spot in the sound due to the garage shape.


A picture of the lighting in the rest of my workshop shortly
 

Kevin54

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Re: My unfinished garage in Vic/Australia

took a picture of my finished bench:

l-asb-bench06.jpg


Now a few things to note-

Jack on bottom left- this is made to slide in at the very bottom, I still need to make something that holds the handle straight up though, the rag is always there so the jack handle doesn't rest against my car pannels when I use it.

Draw hidden in kick pannel at very bottom- I didn't even want to waste the space in the kick pannel so I made a draw for the whole length of it.

Light fittings- this area has it's own light circuit with 3 lights. The light switch is in the corner.

Power- All my power for outlets and lights is in conduits. In the left hand outlet in the picture there is a switch in the middle of it, this then has a conduit go up out of the top to a single outlet. This switch turns my amp on. This saves me going up there to manually turn it off should I want that.

Stereo up the very top- As mentioned above it has it's power remotely turned on and sit's nice on it's own shelf. The small speaker on the to left is connected to the center channel to stop a dead spot in the sound due to the garage shape.


A picture of the lighting in the rest of my workshop shortly

I like that storage bin holder on the left. Great idea :bowdown: I may have to do something along those lines in my garage this year. Nice equipment too. I think the restored lathe looks great!!!
 

AndrewBigA

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Re: My unfinished garage in Vic/Australia

insane wooden tool box storage benches!
keep the pics comming!
 
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sams

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Re: My unfinished garage in Vic/Australia

hey thanks heaps for the encouragment guys. I unfortunetly I have many more plans than I have finished work and right now I have a big mess instead of something I can work with.

For example I don't even have a fabrication table yet, however I did buy a 1 x 1.6M (3.3 x 5.3') plate for the task that's a decent 8mm (0.31") thick. It will also under the main table have 650mm (26") deep draws that will have all my clamps, drill bits, hand tools, etc...

Anyway I have one last new thing which I can show for now which is my lighting system. I am using twin 56W 5' fttings with 6500K globes. I have a very limited cealing height due to issues with permits when my workshop was built so I had to be smart about how I mounted them. I figured the higher the better so I couldn't use a traditional mounting method, instead I did something sneaky:

lights01.jpg


As shown above each fitting is bolted through the end and the brackets themself are individually adjustable so they can be mounted to both C-channel cealing beams. I cut a slot in both brackets and use a pair of 6mm bolts to clamp them together. This way I could lift the light fitting up as much as I wanted, I did however pureposfully leave a gap from the top of the fitting to the cealing for cooling

Also notice in the picture above my obsessive electrical system, no visable cables anywhere. This is a very painfull way of running cables but the safest and also in my opinion the neatest. The outlets on the walls have 30A 240V rated circuits and another of the same for the other side of the garage, surfice to say I have yet to trip the overload.

The Power outlet hiding in the top left of the picture is for my pedastal drill which is freestanding in the middle, I put this there was no way I would permenently run a cable across the ground, covered or not.

Also I fitted way more lighting power than I needed so what I did is split the circuits for each globe inside each fitting. Then I ran twin lighting circuits to every fitting in my garage. This comes from twin light switchs, so it works out as shown below depending on which combination of the two switches I turn on.

lights02.jpg


I rarely use both circuits at once and instead whenever I walk in just turn on one of the two switches randomly. This has the advantage that if I do need a lot of extra light for some reason it's there as a backup.


Seeing people seem to like it I will take another picture of my plastic divider tub storage system in how it's made. I will also write a description on the process I went through to make them. This will help people make their own without too much trouble I would think.

Other plans for this garage is an electric winch off an I-beam that spans the full width of the garage. The winch would be for things such pulling the engine out of my car and would be able to roll down the length of the beam to where I need it.

I am also thinking of learning how to use google sketchup as I have been inpired by Wrnch's build here:

This way I can explain the very specific layout ideas that I have that I think you guys will really like.
 

Kevin54

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Re: My unfinished garage in Vic/Australia

Seeing people seem to like it I will take another picture of my plastic divider tub storage system in how it's made. I will also write a description on the process I went through to make them. This will help people make their own without too much trouble I would think.

Looking forward to that. :thumbup: I'm definitely going to make one then steal the wifes label maker :beer:
 

GTVi

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Re: My unfinished garage in Vic/Australia

This is a great workshop set up well done...neat and tidy, with much thought and planning. Well done.
For the jack handle, perhaps a broom handle holder will do, the type that expands and contracts with a clip to stop it from falling. Go-Lo may still sell them. And perhaps a piece of foam from a rubber shop outlet for the handle instead of the rag. I know I'm nitpicking, but these are just suggestions. I look forward to more details on the storage box design.
 
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sams

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Re: My unfinished garage in Vic/Australia

This is a great workshop set up well done...neat and tidy, with much thought and planning. Well done.
For the jack handle, perhaps a broom handle holder will do, the type that expands and contracts with a clip to stop it from falling. Go-Lo may still sell them. And perhaps a piece of foam from a rubber shop outlet for the handle instead of the rag. I know I'm nitpicking, but these are just suggestions. I look forward to more details on the storage box design.

good ideas, I am always up for suggestions and constructive critism so thanks. The jack handle is spring loaded so I was just going to make a handle that sticks out with a U shape on the end. But I might as well have a look at the product you mention, it's been a while since I have visited a Go-Lo store. I will definately do your foam idea, what I have is a bit ghetto afterall! Any more ideas?
 
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sams

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Re: My unfinished garage in Vic/Australia

Top job, hours of woodwork to.

oh yes many hours indeed, of note all of the front panels of the bench come from one ply pannel all in the right order, so if the gaps where removed the natural wood grain would all line up, it's a small touch but stops it looking all muddled up.

When I make 40 of at 1.2M (4') wide for the back corner of the garage I think I will get quicker, or I seriously hope so!

people let me know if there is anything specific they want to see a picture or want to know about
 
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sams

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Re: My unfinished garage in Vic/Australia

hey I forgot to post this:


It's me making something on my lathe for one of my projects, and before you click on it yes I know I shouldn't of worn gloves.


I have taken some more photos and I will post them when I have a moment
 
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sams

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Re: My unfinished garage in Vic/Australia

Looking forward to that. :thumbup: I'm definitely going to make one then steal the wifes label maker :beer:

ok as requested, this won't be the best description but here goes:

right all you need is two uprights out of just about any material. They need to spaced apart enough so that it's wider than the tubs you wish to fit in and the width of the angled sections, allow a bit extra to make it easy to pull in and out.

Here is mine:

tub-shelf04.jpg


I have two RHS sections going up on the outside but that's only because I wanted a wooden front pannel.

Ok getting started:

- chop 2 angle sections for each tub, setting a stopper makes for quick work on this one.

-
tub-shelf01.jpg


- the first peice: tack weld one section on so it's down the side of the frame, align with spirit level and weld fully, a bar can be slid over the angle to make adjustments later. Start at the lowest position where you will have a tub.

tub-shelf02.jpg


- using a spirit level next to the frame end of the angles mark out where the second angle needs to sit to be level and tack and then fully weld on, adjust where needed. In the diagram above the level is sitting a metal bar so it can reach across.


- Second row and all the rest:

tub-shelf03.jpg



-Have a spacer made of something like wood that is a little thicker than the tubs used, space the next angle off the one below it, weld the end, remove block of wood and align with the level

tub-shelf02.jpg


- using a spirit level next to the frame end of the angles mark out where the second angle needs to sit to be level and tack and then fully weld on, adjust where needed. In the diagram above the level is sitting a metal bar so it can reach across. Note: DO NOT use the block of wood for the second side, or else it's possible to have a cumulative error where the levels are all over the place.

and repeat over and over...

Well I really hope that makes sense or else I will need a video
 

GTVi

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Re: My unfinished garage in Vic/Australia

OK...so far easy to understand, where do you buy these containers from?
 
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sams

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Re: My unfinished garage in Vic/Australia

the good old Reject shop! after a year of keeping my eyes open I find it there out of all places. $5 a go!!
 

ironheadtom

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Re: My unfinished garage in Vic/Australia

Great shop and some really good storage ideas. :thumbup: I've never seen a lathe that old with a d.r.o. on it.
 

NZMacca

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Re: My unfinished garage in Vic/Australia

Awesome work man, interstingly I have that same screwdriver set wal lmounted by my own bench over here in NZ. Really nice shop man.
 
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sams

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Re: My unfinished garage in Vic/Australia

Great shop and some really good storage ideas. :thumbup: I've never seen a lathe that old with a d.r.o. on it.

thanks Tom I hope it gives people some ideas on their own layout. I am all for sharing new ways of doing things and explaining how to do so instead boasting about it.

I thought for a while about installing that DRO on that lathe, afterall it cost around 2/3 of what I originally bought the lathe for before I serviced it and it does look quite odd being such a small machine with one. I also took a serious dislike to drilling into the cross-slide to fit the scale mounting bracket, it really felt wrong to have a machine undamaged for double the length my own age and there I was putting a few holes in it.

However I am really happy that I did as unlike a chinese machine of a comparable size it has the practicality of much larger machines in that it can do decent cuts, has a very good tool height capacity along with quite good accuracy and predictability. It's a real pleasure to use. The only thing that still is an issue is the 4 speeds, I have a variable speed drive and a motor to put on to take care of that though, but for the time being anything that requires a slow speed like large drilling then I use the other lathe I have.

I have more on this machine on my website:

-Hercus Lathe:

Awesome work man, interstingly I have that same screwdriver set wal lmounted by my own bench over here in NZ. Really nice shop man.

thanks, the SCA stores and brand is shared between both our countries however along with much of the same stock. I know this isn't the best quality set but I don't put much stress on my screw-drivers so it works well for me. It is funny though that we ended up doing the exact same thing though.
 
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HSpencer

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Re: My unfinished garage in Vic/Australia

I continue to be very impressed. Thank you for the working drawings on the hardware rack. I can now see where it can be built for a reasonable price in materials. I am ashamed that I have hardware here, there, and everywhere. I must find time to organize it as you have done. Your lighting ideas look great. I also like the conduit lines you have run on the surface of that brick wall. Very professional and neat. It appears you must be a licensed electrician? That is professional work. I hope you will continue to favour us with photos.
 
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sams

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Re: My unfinished garage in Vic/Australia

I continue to be very impressed. Thank you for the working drawings on the hardware rack. I can now see where it can be built for a reasonable price in materials. I am ashamed that I have hardware here, there, and everywhere. I must find time to organize it as you have done. Your lighting ideas look great. I also like the conduit lines you have run on the surface of that brick wall. Very professional and neat. It appears you must be a licensed electrician? That is professional work. I hope you will continue to favour us with photos.

wow thanks, as said earlier I am hoping to be able to help some others on here and share the ideas. Sadly most of the other forums (car related) I contribute in have lots of trivial bickering and arguments, I really like and am impressed by how positive the fellow members have been on here and I wish to contribute to that. This is also why I try and have dual measurements (metric/imperial) for all my posts.

Before you are ashamed of anything might I point out how all my photos are of corners or selected small areas? lets just say at this point in time I don't have a shed for storage and a very large portion of my workshop is full of various boxes and shelves of ****. It's everywhere, I trip over it all the time. The photos make me look deceptively good though hahaha!

Speaking of which I have some interesting plans for a shed I will post the details at the bottom of this post.

Your guess was right, I am a former electrician, an industrial one to be exact, I still have my liecence but I havn't used it officially for a job in 2 years. I do hands on general engineering work now building and servicing thermal road line marking machines. Running everything in pipes is a recipe for pain. Because the cables can't be joined in the boxes at the top they loop the loop from each outlet to the next. I used 4mm^2 cable (standard is 2.5) and only 20mm (3/4") conduits, which is normally an impossible combination. I pureposefully bought TPS/white sheath cable and stripped the outer layer off to run the single insulated cables in the conduits. This way I could physically make them fit (just!) and according to the very fine letter of the law I get a slightly higher current rating. I will take a picture of my sub-board where all the pipes come from. Some observant people when they walk in notice the general wiring, but most don't although they do see an excessive number of power outlets. It certainly doesn't look like 4 months worth of saturdays! However I know I can get a 5kw single to three phase converter and plug it straight in without an issue, well ok maybe after I swap to a higher current outlet in it's place but atleast there would be no issues with the circuit.

Sadly beyond a basic shelf, the board mentioned above and a few other small things I don't have much more photos for the time being. I plan to do some more work once everything has been relocated to my shed once it's built. In the meantime I will have a few small updates here and there and I want to show a diagram of my proposed layout, I will likely draw it later so I can scan it and upload.


Now my proposed shed:

The law says 10 square meters doesn't require a permit/planning permission. So I want to join a shed on to the side of my workshop. To have make the most of the tiny space I have available I will go away from the conventional 3.2 x 3.2 (10.5 x 10.5") box shape and have something 2.5M wide x 4M long (8 x 13'). I am going the narrow width because I can have a 1.3M (4 1/4') central aisle with 600mm (2') deep shelves on either side. At the back end the shelves would open up for the back wall to be full of plastic tubs. I plan for the highest density storage out of anything seen on these forums yet with everything to the celing and using up every last piece of room. I even have a special hoist designed that lifts my trike up, swings out to the side and holds it just off the cealing. I am hoping this is about 4 to 8 weeks away and I will have full progress photos on here.
 

sscustom

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Re: My unfinished garage in Vic/Australia

awsome set up sam

cheers sam . great sams think alike
lol
 

sscustom

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Re: My unfinished garage in Vic/Australia

hey Sam! I am guessing your the guy I am suscribed to in your youtube videos


yeah thats right, hows that hub that you machined coming along any more video coming out
 
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sams

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Re: My unfinished garage in Vic/Australia

no nothing more of late, I am organising my second mill and getting rid of my current non functional one so it will be a little while. I will make a video in about a month but not machining related. Here I do have a project that i think you will like in here:

-My 3x3 trike in the works
 
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sams

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Re: My unfinished garage in Vic/Australia

well I thought I would come clean and show my workshop for how it really is, first up something less encriminating:

main-panel.jpg


This shows my 240V sub board. It has a 50 amp supply (12kw capable) which is fed from the large white conduit into the bottom. On the bottom left is a pair of outlets and my twin light switches on the bottom right.

The small box on the top side houses a phone and network cable which has been run underground.

Now the horror, prepare yourselves as this shows why I am really looking forward to having a shed.


disaster-zone.jpg
 

sscustom

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Re: My unfinished garage in Vic/Australia

keep the pics coming can we see more of those strage containers and whats in them i might do a smiilair set up i went o k-mart this week and picket up bout 8 containers with removable sections so you can organise what goes were

cheers sam
 
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sams

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Re: My unfinished garage in Vic/Australia

sure, right now I only have this one:

l-asb-bench03.jpg


but I can take some more. The ones K-mart sell are $10 each but although much larger they are limited in how many compartments they have, so it can get very expensive and large to have any reasonable collection of things unless you mix them up.

I think it's time to show my milling machine that I don't use, I think everyone will freak out.
 

Topcat

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Re: My unfinished garage in Vic/Australia

Sam it's looking good mate.

I like how you can rough draw then make it, I do the same when planning most tasks.

Nice trike to!!

You've done a great job!!!

Fellow victorian!
 
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sams

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Re: My unfinished garage in Vic/Australia

ok first up my large mill: this is going to sold off for a few reasons. It is a 'copy mill' where the hyraulic joystick on the right hand side follows a 3d template bolted to the table and then one or both the heads machine it on the other. It does a zig-zag 'pick' to determine the shape and where to machine. Without the heads on it it's 1600kg or 3500lb! Very interesting and by the looks of it super rare but not much good for me anymore.


Topcat: thanks, here I have something for you:

shed-plan1.jpg


this is how I like to do things when I am being the most organised, it goes from this backwards to the usual scrap paper scribbles. This is a scale layout of my planned mini shed on some A3 graph paper. On average my concepts end up looking more like this:

spindle-sketch-1.jpg


That trike is quite old now and here is a build of me making an extreme 3x3 version.

So which suberb are you in?
 
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sams

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Re: My unfinished garage in Vic/Australia

sscustom: hey Sam as promised below is the cap head M6 and M8 tubs, I also have tubs for hex head and a shared tub for each size in countersunk and dome head:

l-asb-bench07.jpg



Yonnee: I post to share and give people something different. If I give people ideas on how to make their own garage better then great, this is why I went to the trouble of doing the drawings of how I did the tub holders. I only get joy out of helping and sharing instead of being smug about it with tight lips. Only thing I ask for in return is I get a link or a picture of my concept in action in your own workshop.
 

sscustom

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Re: My unfinished garage in Vic/Australia

sscustom: hey Sam as promised below is the cap head M6 and M8 tubs, I also have tubs for hex head and a shared tub for each size in countersunk and dome head:

l-asb-bench07.jpg



Yonnee: I post to share and give people something different. If I give people ideas on how to make their own garage better then great, this is why I went to the trouble of doing the drawings of how I did the tub holders. I only get joy out of helping and sharing instead of being smug about it with tight lips. Only thing I ask for in return is I get a link or a picture of my concept in action in your own workshop.

sweet cheers ,yeah i am currently getting all my hardware organised into storage boxes just simple stuff like washers,spring washers .nuts and bolts .screws ,im having a stand up shelf monstly full of hardware in storage containers so its easy acess
 

fastbroshi

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Re: My unfinished garage in Vic/Australia

Really like what you've done Sam. And I'm totally jealous of your lathe, despite only having 4 speeds. I have some similar organizers to those and here's what I'm going to do. So I can quickly determine what I have in each bin I was going to make a template to stick to the lid that you can see when you open the top, with a drawing of all the bins and the sizes of the hardware in them, saving you from having to have little scraps of paper in them. Just a thought.
 
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sams

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Re: My unfinished garage in Vic/Australia

fastbroshi: comicly enough I paid $600 for that lathe, I did do some work to it though in repairs. Here is a photo of my other lathe:

335lathe01.jpg


I had high hopes but it's a dissapointment. Due to finances I will stick with it for now and probably mod it to have a crude brake on the motor pulley. Stupid thing is this Lathe is worth $3200 AUD new and it's not very good, it's nowhere near as good in smoothness or accuracy as my 50s Hercus. Although to give it some sort of credit it can do a fairly decent depth cut at once. While your idea is good about the labeling of your tubs there is a very good reason why I have yet to do it- I am constantly reorganising mine as I buy new batches of fasteners. In the future when things are more constant I will look into it.
 
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sams

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Joined
Apr 7, 2010
Messages
266
Location
S.E Victoria, Australia!
Re: My unfinished garage in Vic/Australia

Now in other updates:

Here is a better photo of my slides I use for my draws:

slides1.jpg




Now my sub board:

main-panel.jpg


Power goes out of it for the 2 x outlets at the bottom, 2 seperate circuits for either wall, the light switch and lighting conduit with both circuits in it. The box to above right has an Cat-5 cable inside and phone cable. I didn't think of it at the time but I want to have another double outlet near the entrance of the door under the light switch for when I want to unroll an extension lead out to the driveway. I would have a more permenent light however I will move this lathe once again in the future.


Next up is my improvised steel rack:

steel-stand01.jpg


This was originally made to store 20L storage tubs. The type it was made for is the same as the green and black containers on it now. It's proportioned such that it nicely fits 3 of these in a row per shelf. However I had a need to store my metals and seeing I pretty much overdid it in strength it's more than enough for the job. Once my proper steel rack is made it will return it it's intended function
 

fastbroshi

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Joined
Jul 23, 2010
Messages
111
Location
Dallas, TX
Re: My unfinished garage in Vic/Australia

Sam I'm willing to bet the old Hercus is so much more accurate than the newer one due to the fact that it has so much vibration killing mass (good for heat absorption too). I'm sure you know all this but just throwing it out there for others that might be wondering; I'm learning quite a lot on the web lately.
 
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