Above 1200 Sq/FT The ASYLUM - Happy 40th Birthday to Me! (Est. 2005)

shopnut · Oct 27, 2014

GETTING THE SHOP ORGANIZED (Part 10 of ?)…

LOW PROFILE ROLLING TRAYS FOR UNDER THE CABINETS
I started out cutting the channel to length that matched the width of the trays, but realized I needed to use the channel more sparingly.

So I cut the channel to shorter 3.25” lengths to match a double roller set. It ended up being a lot more ends to de-burr, but hopefully now the wheels will run out when I ran out of channel. In this picture, I also have some of the lumber cut to size.

Six of the 8 trays built.

Now all 8. Roller channel and plywood floors have been added.

I decided to initially spray the trays. I made a cardboard box to tightly fit inside it so overspray wouldn’t go everywhere I didn’t want it to.

The paint dried really fast on the 80F day with a little breeze. It was a perfect day to be outside tinkering.

It’s tough to get a consistent glossy paint job on wood with a spray can, so I lined them all up and brushed on a final thick coat of black on the front face that will be seen.

Even that thick final coat dried so fast I didn’t have a chance to drink a beer while watching it dry. On to assembly...

shopnut · Oct 28, 2014

GETTING THE SHOP ORGANIZED (Part 11 of ?)…

LOW PROFILE ROLLING TRAYS FOR UNDER THE CABINETS
The paint dried so fast, I was able to roll right into final assembly. Rollers and drawer pulls where added to each. There are two different sizes because a 6x6 column protrudes into the path of three.

The tray underbelly showing a little more detail on how I built them. The wheels float in that special channel and a 2x2 mounts between them to hold the wheels in place.

Since they take up nearly all the room under the cabinets, a drawer pull was necessary.

Under the cabinets in their new home. I considered painting them yellow, but figured they will get beat up a little down there while sweeping, so black will be easier to touch up. You can barely notice them down there, so I guess that is good.

I emptied out two bins worth of misc. metal stock and brackets into those 8 trays.

Note that I made the trays narrow enough to allow the cabinet casters to swivel fully without hitting them.

akdiesel · Oct 29, 2014

shopnut

Those turned out great. If you feel the need, I have had good luck with the rattle can Truck Bed Spray liner from Lowes / HD. It may help to prolong the wood inside the drawers.

shopnut · Oct 29, 2014

akdiesel said:
shopnut

Those turned out great. If you feel the need, I have had good luck with the rattle can Truck Bed Spray liner from Lowes / HD. It may help to prolong the wood inside the drawers.

There has been so many times when I thought to myself "THIS would be the perfect application for that bedliner stuff", and then I didn't have it handy so I did something else. Okay, time to buy a can so I will be prepared for next time. Thanks.

shopnut · Oct 31, 2014

GETTING THE SHOP ORGANIZED (Part 12 of ?)…

Fastener Cabinets
I like keeping certain things in portable organizers that I can carry over to the jobsite, like wire nuts and drywall screws. I also like to kit up parts that require special tools, like electrical terminals and the various matching crimpers. But when I comes to general fastener storage, my preference is having big old drawers to hold all those nuts and bolts. It's great to pull out a drawer with all your 1/4-20 screws in it, for instance, and have a clear view of all the choices for your project. Having it all contained within a cabinet keeps the bins from filling up with dirt and keeps the overall shop looking tidy by hiding it all.

I've used this 4-drawer 40" wide cabinet for fastener storage in my city garage for about 15 years now and it is holding up great. Four Plano 3700 series organizer fit in each drawer perfectly and still allow room for oddball sized parts around the perimeter.

I was perusing ebay the other day and stumbled upon two more cabinets just like it and soon they were on their way via FedEx. They were slightly beat up in transit (big surprise there, right!) and a little hammering and straightening got them back to like new condition. To be honest, I think they weren’t ever used because the drawer pulls and drawer interiors do not have a single scuff or scratch on them.

Drawers pull out full so there is no inaccessible space (I hate wasted space

).

One design difference between my old cabinet and the new ones are removable front panels on the drawers. It's going to make painting them ASYLUM yellow much, much easier by not having to fumble around with the entire drawer.

Now where did I put my spray paint.

dailybreadbaker · Oct 31, 2014

whats the maker of those cabinets?

JCQuick · Oct 31, 2014

yellow spray paint would be in the Y section lol just thought I would help

taumac · Oct 31, 2014

Re: The ASYLUM - Turning a Crazy Vision into a Lakefront Gearhead Getaway: Year 6

I would check the spreadsheet for the location of the yellow paint. LOL

Have a good one, Gerard

shopnut · Nov 2, 2014

dailybreadbreaker - Luxor, but they only seem to sell A/V and other carts these days.

JCQuick/taumac - You guys are a BIG help!

What you didn't realize (or maybe I didn't tell you?) is that I'm doing the paint job at my other garage - the one that could use a bit more organization it seems

.

shopnut · Nov 3, 2014

GETTING THE SHOP ORGANIZED (Part 13 of ?)…

Fastener Cabinets
Well, I found my yellow paint. I was painting the drawer fronts in the evening after work, but by the time I sprayed the last few, bugs started being a problem. Arg! I had to use a tweezers to pluck a few out of the wet paint, but I got through it. After I got done, my wife suggested using the mosquito repellent candle. Good idea, but a little too late! Next time, for sure. Here they are drying in the humidity-controlled guest bathroom.

The morning before I hauled the cabinet to the ASYLUM, our community was having a their big garage sale. It was a nice day for a bicycle ride so I thought I would just loop around the block and check it out. Just down the street I found a heavy duty rolling cart like the ones you might use at Home Depot or Lowes. For $50 I was rolling it home. I'm sure there were a few people that thought I was wheeling it around the neighborhood looking to load it up with garage sell finds

.

The timing was perfect because the cabinets fit on it nicely. It will make it easy to move them around in the shop until they get positioned in their final spot below one of the windows.

JCQuick · Nov 3, 2014

we had an estate sale down the street I bought a cool 4 wheel old edger for 42.50 proceded to hold it out the window of my street bug back to the house. Do you have any idea what an edger handles like at 20 MPH being pulled backwards. Oh and if my left arm lets go its wont be good for either the car or the edger LOl

shopnut · Nov 5, 2014

JCQuick said:
we had an estate sale down the street I bought a cool 4 wheel old edger for 42.50 proceded to hold it out the window of my street bug back to the house. Do you have any idea what an edger handles like at 20 MPH being pulled backwards. Oh and if my left arm lets go its wont be good for either the car or the edger LOl

Funny! I bet the wheel bearings of that poor edger weren’t real happy with the whole situation either

nine4gmc · Nov 5, 2014

Those cabinets are SLICK, what brand?!?!?! Great job on fixing them up and nice find on that cart too!

shopnut · Nov 5, 2014

nine4gmc said:
Those cabinets are SLICK, what brand?!?!?! Great job on fixing them up and nice find on that cart too!

Thanks. I bought the first cabinet like them many, many years ago, but never knew the maker. I always wanted some more. These recent ones I bought where labeled with Luxor. There isn't much of a need for drawing cabinets anymore so apparently they stopped making them :dunno:

. Funny thing is, that original cabinet started out with a black housing and yellow drawers. I painted the drawers red to match my old Craftsman stuff. Soon it will return to yellow when it moves to the ASYLUM.

Thanks for stopping in.

shopnut · Nov 5, 2014

SAY GOODBYE TO THE 26 GALLON COMPRESSOR…

The 60G compressor is now finished so there's no reason to trip over this other compressor any longer. I promised it to a good friend and I'm sure it will be put to good use. She has served me well. It was a cool compressor because it was designed to sit horizontally or vertically. Here it is right before and after it got hoisted onto the truck.

I got this little portable unit in trade, and it will reside down in the garden shed so I don't have to keep carrying the portable tank down there to fill up tires.

He also had a nice 1/2"NPT regulator and filter to donate to the ASYLUM and I'm sure it will be put to good use.

taumac · Nov 6, 2014

Re: The ASYLUM - Turning a Crazy Vision into a Lakefront Gearhead Getaway: Year 6

Got a question. Did you cut the top of a top chest here.

Have a good one, Gerard

shopnut · Nov 6, 2014

What you are seeing in the background of that picture is a short roller cabinet with a 3-drawer full depth intermediate cabinet and 9-drawer 12" deep chest on top on it. I found this old blurry picture when it was still at the other place which might explain it a little better.

I bought that intermediate cabinet right when Craftsman introduced the ball bearing slides and liked it so much that I converted the bottom box to ball slides as well that extended all the way out, unlike the originals that left about 1" of drawer inside the cabinet.

It has served me well over the years.
.

taumac · Nov 6, 2014

Re: The ASYLUM - Turning a Crazy Vision into a Lakefront Gearhead Getaway: Year 6

Oh I see now. Wow Ive seen some full depth chests but I've rarely seen a full depth intermediates. I guess I've got to stop by sears more often. I bought my homeowner grade set back in early 90's and havnt got another "new " tool box until my 44's.

Have a good one, Gerard

shopnut · Nov 6, 2014

Looking back at my old Craftsman catalogs, it appears as though I bought the intermediate in 1996 - WOW, 18 years ago. How time flies!

taumac · Nov 7, 2014

Re: The ASYLUM - Turning a Crazy Vision into a Lakefront Gearhead Getaway: Year 6

Time sure does. I thought about putting ball bearing slides on some of mine. How tough was it? Did you have to cut out the old friction slide or did you find ones to fit the channel on drawers and box? My vintage craftsmans work ok with the friction slides but that DP cart has real crappy friction slides like the home owner grade boxes came with. I used to have to bend them back in place all the time if I leaned on them or I wasn't careful closing drawer. What a PIA that was.

Have a good one, Gerard

shopnut · Nov 8, 2014

CONVERTING AN OLD CRAFTSMAN TOOLBOX TO BALL BEARING SLIDES…

Hopefully this will explain it taumac (and anyone else thinking about it).

Years ago, I decided to convert my old Craftsman toolbox over to ball bearing drawer slides. A much better action resulted and the drawer ended up with a greater slide distance for full access to the contents.

The compound slide half that is spot welded to the drawer had to be removed. I did this by drilled out the welds. Pick a drill bit just a little bigger than the weld. The arrow points to one, but there was 5 or 6 per side. I added some edge trim to more or less hide the holes.

The other half of the compound slide did not need to be removed and remained in the cabinet. It worked nicely as a reference to mount the new ball bearing slide. One arrow points to the old slide that was not touched and the other points to one of the screws that mounts the new slide.

Here is one of the screws that holds the new slide to the drawer.

And here it is inside the drawer.

Although the screws holding the new slides inside the cabinet protrude outside in a non-obtrusive place, they are definitely visible where I drilled them.

Another shot of the finished ball bearing slide. I don't remember where I got the slides (it was +15 years ago!) but they had a nice latching system that allowed the drawer to be removed from the cabinet easily.

The trickiest part (from what I remember) was just making sure the drawers all were spaced evenly when finished. This cabinet only had 3 drawers to it was relatively easy, but be careful on those with more as it could become a real pain.

taumac · Nov 9, 2014

Re: The ASYLUM - Turning a Crazy Vision into a Lakefront Gearhead Getaway: Year 6

Thank you so much for that write up. That sure explains that process you went through to convert those over. I do know that HD and Lowes do offer ball bearing slides now. Thanks again

Have a good one, Gerard

shopnut · Nov 10, 2014

You are welcome.

shopnut · Nov 10, 2014

GETTING THE SHOP ORGANIZED (Part 14 of ?)…

When it rains, it pours. I stumbled upon some more matching cabinets and couldn't resist. They are made up of the same 11" tall modules so I can mix and match them as needed. These have taller 5" drawers and should be great for storing all kinds of stuff. I bought the two stacks of 4 they had and they are getting freighted in this week (hopefully). I'm curious to see how sturdy those pedestals are - they may come in handy for my lathe or my future bench mill. Of course, I will need to add doors to them somehow so all that space under there doesn't go to waste!

Here are some pictures of them sitting at the sellers place.

Each drawer is filled with these little 3x3 boxes (and wire rack system), 1700 of them to be exact! I'm sure I will figure out a use for some of them, at least. They will lay flat in the shallow 2" drawers so maybe a few more can be used there. It looks like they were stuffed with some kind of parts, but the auction said they would be empty when the buyer receives them. Darn, who knows what treasures might have been in there

.

bj383ss · Nov 11, 2014

Great score on those new cabinets. 1700 containers to sort things. That would keep me up at night trying to figure out a rhyme and reason. Great idea on converting the craftsman to ball bearing. Add that to my list. I definitely can tell the difference between my Craftsman bottom and Proto. Especially once it has a lot of weight in it.

Not to hijack or anything but here is a link to real great priced slides that I have used on all my drawers I have built over the last 8 years. Beats the buying them at the big box.

http://www.wwhardware.com/kv-tt100-economy-100-lb-full-extension-drawer-slide-kvtt100

taumac · Nov 11, 2014

Re: The ASYLUM - Turning a Crazy Vision into a Lakefront Gearhead Getaway: Year 6

Man those are gonna be nice addition to your shop. They have 1700 little boxes to store stuff? That's about 1700 reasons you sure have the right name for your place. LOL. Looking for to seeing how you put them to use.

Have a good one, Gerard

jkherd · Nov 11, 2014

shopnut said:
CONVERTING AN OLD CRAFTSMAN TOOLBOX TO BALL BEARING SLIDES…

Hopefully this will explain it taumac (and anyone else thinking about it).

Years ago, I decided to convert my old Craftsman toolbox over to ball bearing drawer slides. A much better action resulted and the drawer ended up with a greater slide distance for full access to the contents.

The compound slide half that is spot welded to the drawer had to be removed. I did this by drilled out the welds. Pick a drill bit just a little bigger than the weld. The arrow points to one, but there was 5 or 6 per side. I added some edge trim to more or less hide the holes.

The other half of the compound slide did not need to be removed and remained in the cabinet. It worked nicely as a reference to mount the new ball bearing slide. One arrow points to the old slide that was not touched and the other points to one of the screws that mounts the new slide.

Here is one of the screws that holds the new slide to the drawer.

And here it is inside the drawer.

Although the screws holding the new slides inside the cabinet protrude outside in a non-obtrusive place, they are definitely visible where I drilled them.

Another shot of the finished ball bearing slide. I don't remember where I got the slides (it was +15 years ago!) but they had a nice latching system that allowed the drawer to be removed from the cabinet easily.

The trickiest part (from what I remember) was just making sure the drawers all were spaced evenly when finished. This cabinet only had 3 drawers to it was relatively easy, but be careful on those with more as it could become a real pain.

Where did you get the slides that you used from? I need to install bearing slides on my tool box and this article will be very helpful. Thanks. :thumbup:

shopnut · Nov 11, 2014

bj383ss – Thanks. I’m not entirely thrilled with the price I paid for the cabinets, but it was a decent deal. You are right about the weight in the drawers – ball bearing slides really start feeling good when the load gets heavy.

Thanks for the link on the slides – seems like a good deal. I’m just starting to plan out my main workbench and while most of it will be made up of purchased cabinets, there are a couple custom-sized drawers I want to build to squeeze some more storage space in. These will require some long slides.

taumac - I need to reserve a few of those boxes for storing marbles - Some people say I lost mine many years ago! LOL.

The plan right now is to put 3 modules (each module being 11 inches high) under each window. That will us 9 of them.

jkherd - It was about 15 years ago when I did the slide conversion so I don't recall exactly where I got them, probably the local surplus store. Member taumac said HD or Lowes has them and bj383ss gave a link to some reasonably priced ones online so you might check some of those sources out. Hope it helps.

jkherd · Nov 11, 2014

shopnut said:
bj383ss – Thanks. I’m not entirely thrilled with the price I paid for the cabinets, but it was a decent deal. You are right about the weight in the drawers – ball bearing slides really start feeling good when the load gets heavy.

Thanks for the link on the slides – seems like a good deal. I’m just starting to plan out my main workbench and while most of it will be made up of purchased cabinets, there are a couple custom-sized drawers I want to build to squeeze some more storage space in. These will require some long slides.

taumac - I need to reserve a few of those boxes for storing marbles - Some people say I lost mine many years ago! LOL.

The plan right now is to put 3 modules (each module being 11 inches high) under each window. That will us 9 of them.

jkherd - It was about 15 years ago when I did the slide conversion so I don't recall exactly where I got them, probably the local surplus store. Member taumac said HD or Lowes has them and bj383ss gave a link to some reasonably priced ones online so you might check some of those sources out. Hope it helps.

Thanks for the help, I really appreciate it. :beer:

shopnut · Nov 12, 2014

jkherd said:
Thanks for the help, I really appreciate it.

You are welcome. Thanks for the beer - I never turn that down!!

shopnut · Nov 12, 2014

GETTING THE SHOP ORGANIZED (Part 15 of ?)…

The cabinets arrived at the freight terminal in record time (I was a little late making the last post about them so don’t think they showed up THAT fast). As I did with the auto lift pickup, I decided a flatbed trailer was the best way to transport them to the shop. Unlike last time however, U-Haul had a trailer that would suffice so I chose them instead because one of their rental stores was right down the street.

Here I am at the freight terminal picking up the package.

Not long later, I arrived at the ASYLUM ready to unload. It was a beautiful 75F day.

The pallet of cabinets weighed in at 1,020 pounds and this is about twice as much as I ever lifted with the crane. In fact, the electric hoist was only rated for 1,000, so I wasn’t even sure if the old girl had the power to lift it. But I decided to try lifting the whole thing at once and had a fall back plan of tearing apart the packaging and hoisting each cabinet separately.

Rather than taking any more chances than necessary, I added a safety strap to the jib crane arm. A means of reinforcing it was planned from the beginning for these rare occasions so I thought I finally ought to try it. Personally, I think it is a preety slick set-up, in that it is completely hidden from sight when not in use. I added some D-rings in the rafter above the crane years ago and they are accessed by sliding a ceiling panel. (see Reply 2237)

Although one panel slides to expose all of three openings, I was only going to use the one above the end of the crane arm this time. I used a Come-a-Long and a strap this time, but because it was a bit of a pain rigging it up, I just placed an order for parts to make it much easier next time. And the new set-up will position the strap nearly vertical as opposed to the nasty angle I used this time which added more load in the strap than necessary.

With the crane reinforced, it was time to see if the hoist was up to the challenge. I also found out I didn't really have the best rigging for lifting a tall load like this, so those parts are also on order for next time.

Here's another shot from the stairs window.

I'm ready to lift it off the trailer!

mdbeck1 · Nov 12, 2014

shopnut said:
GETTING THE SHOP ORGANIZED (Part 15 of ?)…

The pallet of cabinets weighed in at 1,020 pounds and this is about twice as much as I ever lifted with the crane. In fact, the electric hoist was only rated for 1,000, so I wasn’t even sure if the old girl had the power to lift it.

You say that the hoist is only rated for 1,000 lb. As an engineer you KNOW that all you have to do is use a ****** block and clip the cable back up to the hoist/jib crane to DOUBLE the lifting capacity of the hoist. Of course that causes you to use TWICE the cable.

shopnut · Nov 12, 2014

I kind of have that covered mdbeck1, but not quite :sad:

.

If you look at the picture below, you will see an extra trolley on the beam that would allow doubling the chain back up the beam and still allow the set to roll down the length of the beam. I got lucky when I found that electric hoist because it had 20 feet of chain on it (most have 10 or 14') and that allows it to nearly reach the ground even when doubled up. I even found a nice high quality chain block on ebay for pennies (well, maybe $30). The only problem is, the pitch of the block sprocket is just a little bit off from the pitch of the chain, and I'm leery it will jamb at the worst possible time.

As an alternative to the second beam trolley, I discovered the hoist was available in a 1-ton version and the only real difference is the chain doubles back directly to the hoist housing itself. I ordered the chain anchor parts, only to cancel the order after a couple months because one of the vital parts was backordered. I'm still looking for a source for that because it's really the cleanest way to do it.

Whatever I finally come up with, I want it to be quickly convertible. That doubled lifting power also comes at the price of cutting the lift speed in half. And I don't think I want it running that slow for the typical lightweight duties around here.

shopnut · Nov 13, 2014

GETTING THE SHOP ORGANIZED (Part 16 of ?)…

The crane and electric hoist did me proud when they didn't even seem to struggle. It put a smile on my face. Since the crane arm was locked in position, I lifted the load off the trailer and then drove it out from under it. You will notice the lifting straps bypassed the somewhat questionable wood pallet and wrapped around the cabinet directly. The pallet was more or less dragged along for the flight by the metal shipping bands.

Trailer pulled out from under it. I stopped to send a text/picture to my wife, and she replied "Great – NOW PUT THAT THING ON THE GROUND!!!”

After some unwrapping. Keep in mind, I had just seen a few pictures online, so seeing it for the first time was a big deal. The seller had done a great job of protecting the cabinets and I was not disappointed upon seeing their condition in person.

I lifted them one by one off the pallet and set them each down on some HF carts so I could move them around temporarily. I nearly had a bad mishap when I moved the first one and had the drawers start opening after unstrapping it. We all know bad things happen when too many drawers open at once. I felt like the guy that was trying to plug one hole with his finger, only to have a another leak start somewhere else - at some point you run out of appendages to seal them all

. So it went with me pushing in drawers - I would push one in and another started rolling out. I ended up leaning my body up against the whole thing while I took a deep breath and tried to figure out what to do.

I found something within reach to hold the drawers shut temporarily until I could retrieve some tape. Once in their permanent spot, I don't think it will be a problem. I guess the installed key latches are the method for keeping them shut, but I don't have the keys to lock them. I guess the good news out of all this is that the drawer roll open very, very smoothly

.

As with the other smaller cabinet, the drawers open full extension. Here is one showing the cases inside. It looked like they had never been used. The white paper underneath them had numbers labelling each one so I guess you could return them to the correct slot.

But this is when my day went from good to great! Much to my surprise, only 3 of the 16 drawers were empty like this. The others were stuffed with goodies. I honestly did a happy dance right there on the shop floor.

3200-Luxor-Cabinets-129 (Cabinet 1 Drawer 7).JPG

Now, let's see just what kind of treasures are in there.

IGO2XS · Nov 13, 2014

Shopnut, you sure do have some fancy drawers there :thumbup:

I am jealous.

shopnut · Nov 13, 2014

IGO2XS said:
Shopnut, you sure do have some fancy drawers there I am jealous.

Haha - Usually I try to keep my drawers out of plain sight. But for a change, I'm going to show them off to the world!

BTW, they came from good old Indiana.

Vernmotor · Nov 13, 2014

Ok come on ! what in there ? Me happy too/ I was think maybe they get tire of taking stuff out and leave it ! LOL

shopnut · Nov 13, 2014

Vernmotor said:
Ok come on ! what in there ? Me happy too/ I was think maybe they get tire of taking stuff out and leave it ! LOL

Okay buddy, I'm staying up late so I can get the next set of pictures posted. (This stuff doesn't write itself, you know). Don't get too excited though. It not necessarily what's in it, it's the potential worth of it.

You are right, I believe the seller maybe got a little lazy or rushed. He said he thought I might be able to make use of some of it so he left it in there. He got that right! (in more ways than one

)

shopnut · Nov 13, 2014

GETTING THE SHOP ORGANIZED (Part 17 of ?)…

The seller told me these cabinets came from a General Electric motor assembly plant. Looking at the parts, I would say they resided in some kind of repair shop for their electrical test equipment because they are filled with all sorts of parts for Fluke, Tektronix, and HP brands. Things like replacement LCD display panels, switches, and internal components.

There are also many "generic" repair parts like resistors, rectifiers, transistors, LEDs, capacitors - you name it! And lots and lots of integrated circuits (you know, those little computer “chips”) – about 5 drawers worth, thousands I suppose. Everything was labeled very well with part numbers and sometimes even specs on the plastic boxes. Many things are still sealed inside individual bags and boxes.

Curiosity started getting the better of me and I looked up a few part numbers. Some of it is pretty high dollar stuff and here is an example of a few things found on a website specializing in new/used electronic parts.

3203-Luxor-Cabinets-31 (Example prices).jpg

Each drawer has its own lock and they would be a good way to avoid having drawers inadvertently rolling out in the future. Unfortunately, I don’t have the correct keys and the locks are currently locked open. I guess that’s better than being locked shut, but I would still like to use this somehow as simple latches to hold each drawer shut. I need to start looking for latches that fit in the same hole but just have knobs instead of a keyed cylinder.

And here’s a final picture with all the new cabinets together. Although they are already yellow, the drawers of the big ones will get a matching coat of brighter paint before too long.

(Okay, now I'm going to bed!!!)

tinbender 66 · Nov 13, 2014

Nice score!

Above 1200 Sq/FT The ASYLUM - Happy 40th Birthday to Me! (Est. 2005)

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