Barry Builds His Dream Shop

[Bib Overalls]

Barry's Shop 140 by Bib Overalls, on Flickr

For the past couple of days Barry has been working on paying jobs. He was going to sand blast a couple of customer tanks today but the humidity was to high. So we worked on welding tables in the old shop. This is the second table that he built out of old factory tooling. This one required a little more work. The top was originally at a 45 degree angle and it had to be cut off and reset. Two legs had to be cut down and two had to be extended. When the job was done Barry dropped a large ball bearing on the top. It bounced but did not roll off. Pretty good for torch and grinder work.


Barry's Shop 141 by Bib Overalls, on Flickr

While Barry was working on the welding table I took some of the cut offs and cut them up to make this stand for the Burr King 760 belt sander Santa brought me for Christmas. The Burr King stand cost $350. All I have in this is time. Once I have my machine in hand I will add a work tray and belt rack similar to the one Burr King sells for $180. FYI the post is 4" square 1/4" wall tubing. The feet are 2" by 3" rectangular 3/16" wall tubing and the top plate is 1/2" thick. Stout.

 

[sreno]

A wonderful shop; superbly documented!

Thanks to both of you!

Shawn

 

[Bib Overalls]

Not much of an update but progress none the less. After a bit of a lull due to the holidays, paying work, and nasty cold weather we are back at it. Today we tackled the main electric panel. The old shed had a 200 amp service and when it was put in it was mounted to one of the angled side posts. With the wall removed the panel needed to be relocated to the new, nearby vertical wall. The first step was to install a plywood back panel. This protects the insulation behind the panel and provides a good mounting surface.


Barry's Shop 142 by Bib Overalls, on Flickr


Inside, the panel was a mess. All of this will be sorted out as we rewire the entire building.


Barry's Shop 143 by Bib Overalls, on Flickr

The panel in it's new home. Getting it moved required cutting the 2" PVC conduit with the feeder wires inside, gluing in a 22 degree sweep. The hardest part was fighting the 4o feeder cables out of the box and then back into place. We have a ligting circuit, a couple of outlet circuits, a compressor circuit, and a welder circuit temporarily jury rigged. When the rewiring is finished all of the Romex will be replaced by THHN in conduit.


Barry's Shop 144 by Bib Overalls, on Flickr

 

[Deadhead]

Bib - what plant did all that equipment come out of. Looks like a place heading out toward Lake City on the right. I dont keep up with the machinery auctions like I used to when I was at the previous job at a machine shop here in Walnut Ridge. Great looking stuff that he bought, makes me wish I still had all those cool toys to play with

 

[Bib Overalls]

Barry got the stuff in this thread from an auction near Union City, Tennessee. It was stock that some machinery resellers had accumulated from several sources. Normally, they price and sell but in this case the building sold and the contents had to go. He got some good deals.

I'd tell you to drop by his current shop in the hanger at the Bono flying service. But this time of the year and with the new shop project up on the hill it is hit or miss.

 

[Dara]

looks like its going to be a great workshop...we need more pics

 

[jefsocmw]

Did you have any issues putting the wall panels on over the insulation? I've purchased a Mueller 30x40x12 bolt-up that I plan to put up with the help of family and friends. People have told me the most difficult part is putting the panels on with insulation, do you have any tips or tricks to doing it?

 

[Bib Overalls]

Should have some more pictures shortly. We are about to start wiring. Project includes a 25 HP rotary converter making three phase for the machinery.

There is really no secret to screwing down the tin over insulation. You do have to be attentive to the details. First, the insulation goes on with the tin. Don't put up insulation until you are ready to cover it with tin. Each section of insulation needs to be stretched taunt and secured to the adjacent section. Spring clamps and small pieces of two sided tape are useful in this regard. Some insulation needs to be taped on the seams but most come with an edge that has an adhesive strip covered with a peal off. Second, screw the edge of the tin at the overlap from top to bottom and then work across the field. Use a level to check alignment and make adjustments as necessary. Pre-drilling holes keeps the screw heads aligned and makes starting the screw easier. You can buy a putty or calking that comes in rolls to seal the tin at the overlaps. Not necessary on walls or steeply pitched roofs but highly recommended for low and near flat roofs. Something to discuss with Mueller. A battery powered impact driver is the tool of choice. Make sure you have several extra drivers on site. Get the ones that have a magnate to hold the screw heads. Drivers will wear out and they have an uncanny ability to get lost.

 

[jefsocmw]

Thank you for the response, that gives me a more clear picture of the process and lessens my stress about doing the job. The shop build looks like it is coming along great, it is great to see something documented so well. I hope to do the same with mine.

 

[Bib Overalls]

After a a delay due to bad weather and money making work Barry was able to put a long weekend into the shop building.

Barry is always looking for good deals on used machinery. Last week he latched on to this large radial arm saw with hydraulic feed. He will use it to cut aluminum C-channel for the boats he builds.


Barry's Shop 145 by Bib Overalls, on Flickr

At the same time he got this large capacity horizontal band saw.


Barry's Shop 146 by Bib Overalls, on Flickr

Recent focus has been on getting the shop wired up. The concept calls for a main trunk down the center feeding 240 welder outlets, 120 utility outlets, and ending at the three phase converter. This is the first section made out of 3" PVC conduit


Barry's Shop 147 by Bib Overalls, on Flickr

The 3" conduit runs to the first post where it terminates in a PVC junction box. Branch conduits run over to and then down to outlets.


Barry's Shop 148 by Bib Overalls, on Flickr

Smaller PVC boxes are used to further split the runs.


Barry's Shop 149 by Bib Overalls, on Flickr

At the first post the main trunk conduit is reduced to 2" and run to the second post.


Barry's Shop 150 by Bib Overalls, on Flickr

Another drop for outlets.


Barry's Shop 151 by Bib Overalls, on Flickr

The main trunk conduit ends at the Phase-Craft 25hp rotary converter panel. Barry scored this three phase breaker box at an auction. All of the various three phase machines will be wired from this panel.


Barry's Shop 152 by Bib Overalls, on Flickr

All of those high load circuits require heavy conductors. It took three men pulling and pushing to get it all in place.


Barry's Shop 153 by Bib Overalls, on Flickr

It got to dark to make up the panel and boxes so a little time was spent wiring up the first of five mercury vapor lights in the high bay.

It got too dark to make up the panel and boxes so a little time was spent wiring up the first of five mercury vapor lights in the high bay.


Barry's Shop 154 by Bib Overalls, on Flickr

One side of the 2nd post. Two 50 amp welding circuits and a duplex utility outlet. The other side of this post will get two three phase welder outlets.

Barry making up the panel at the end of day two..Shortly after this picture was taken attention turned to a which is better, Coors Light or Bud Light.


Barry's Shop 156 by Bib Overalls, on Flickr

 

[JTH]

glad to see this back! Wont be much a man couldn't get done with Barry's equipment. Hope we see some boat building pics soon. JT

 

[Bib Overalls]

glad to see this back! Wont be much a man couldn't get done with Barry's equipment. Hope we see some boat building pics soon. JT

Barry has a boat in the jig. He is backed up right now with orders for the stainless steel mixing tanks he builds for agricultural flying services. The guys will be flying fields in a few weeks and he needs to get them finished up. I'll get some pictures for you the next time I go over.

 

[TexasT]

Wow, that is a nice shop ya'll are puttin together.

 

[Bib Overalls]

People have been asking me about the products that Berry builds and his need for all of the equipment he has acquired and the space he is building. I took this picture today at the old shop by the air strip. In the front you can see the start of two 250 gallon stainless steel mixing tanks. In the back a 130 gallon model. These tanks are used by farmers and agricultural flying services to prepare (dilute and mix) applications for spraying.


Barry's Shop 157 by Bib Overalls, on Flickr

The tanks get full covers, wash down plumbing, and jug washers standard. All liquid containing welds are TIG. Other welds are MIG with stainless steel wire. So far this spring Barry has delivered three of the 130 gallon tanks and has orders for ten or twelve 250 gallon models. He also manufactures custom tankes for automotive and other agricultural and industrial purposes. And then there are boats, boat repairs, custom trailers, truck wheel base shortening and extending, etc. Quite a guy.


Barry's Shop 158 by Bib Overalls, on Flickr

Not spam. I'm just bragging on my friend.

 

[Vieux]

Great shop with good equipment!

 

[truckin23]

Just finished reading from the beginning subscribing awesome

 

[Bib Overalls]

I have not been out to Barry's shop for about a week. Mostly because I went down to Austin, Texas for the Lone Star Roundup. This evening I got out to the shop and the first thing I noticed was the new T8 quad florescent lights in the future fabrication area. They really light the place up.



The start of the compressed air distribution system.



Shed roof over the back door, rotary converter and air compressor.



It has been raining for several days and even with a little wind the equipment has remained dry.



The south wall has been paneled with salvage sheet metal and wired with quad outlets at the posts. The metal storage racks will be located here.



This evening we ran some more wire for three phase welding outlets and machinery. Good friend Roger and I cut the wire to length.



Barry setting up the second pull. We had the welding outlets (#8 red) wired up and tested before we quit for the night. The equipment power (#10 yellow and orange) will be connected when the machinery is in place.



At this point the general electrical wiring is almost complete and the compressed air system is starting to shape. Barry should start placing machines by this weekend. Stay tuned.

 

[Bib Overalls]

This is a busy time of the year for people in the agriculture business. Barry has been working long hours on chemical mixing tanks, tractors, and the like. Even so, he has managed to get a few hours in on his new shop. Lighting in the machine shop area was finished up.

Barry's Shop 166 by Bib Overalls, on Flickr

The rest of the ridged foam board insulation ceiling was fitted and wiring was brought in for several 220V single phase machines that will be located in this area.

Barry's Shop 167 by Bib Overalls, on Flickr

The floor was painted with a material used in aircraft hangers.

Barry's Shop 168 by Bib Overalls, on Flickr

Then work started on the ridged iron pipe compressed air distribution system. The main lines are 1", the drops are 3/4", and the drip legs are 1/2". Barry and Rodger have been best friends since kindergarten and when they are working together it is best to stand aside and take pictures.

Barry's Shop 169 by Bib Overalls, on Flickr

Fitting a length of pipe for the system's trunk line.

Barry's Shop 170 by Bib Overalls, on Flickr

Tightening up a joint.

Barry's Shop 171 by Bib Overalls, on Flickr

A finished drop.

Barry's Shop 172 by Bib Overalls, on Flickr

This drop will feed air to the plasma cutter and also to the shear.

Barry's Shop 173 by Bib Overalls, on Flickr

First machine to be placed in it's final position. This is a 10' shear that gives Barry the ability to cut full sized sheet metal the hard way. It is a big machine and it looked huge on the trailer. Setting in the big shop it looks rather petite.

Barry's Shop 174 by Bib Overalls, on Flickr

 

[im_lower]

Watching.

 

[Canadian Charlie]

What an impressive shop, can't wait to see whats next

 

[ADSR]

Forgot about this thread. Glad to see it up top again!

 

[Krokodil]

Great shop!

 

[SILVERPLATE]

Barry is doing an awesome job. Great photos and write-up, keep it coming.

 

[930dreamer]

WOW, how did I miss this thread? I would have loved to help do something on this project (free labor). Great build and I like to way things are done in Arkansas.

 

[MagKarl]

Definitely one of the best threads here. You have to marvel at guys like Barry.

 

[Bib Overalls]

The hard part of the job is over. The new building is up, wired, and plumbed for air. The original shop, which was incorporated into the new structure, will be used as a general fabrication area. It needs some wiring and insulation and the construction of a small bathroom. This week we should start moving and placing the lathes, mills, and other heavy equipment. I'll have an update for you in about a week.

 

[1/2 Cup]

Thanks for the update and a great thread, looking forward to seeing all the equipment in place.

 

[Bib Overalls]

Went over to Barry's yesterday thinking we would sit around a bit and enjoy the Memorial Day holiday. I found Barry motivated. Last night he took some cardboard and laid out the location of his various machines in the shop. He was raring to go.

Barry's Shop 175 by Bib Overalls, on Flickr

We decided to move in the two largest pieces of equipment; the 12' bed Leblonde lathe and the 36 ton, 8' Chicago press brake. To get started some of the smaller macines had to be moved out of the way.

Barry's Shop 176 by Bib Overalls, on Flickr

The lathe had to be pulled away from the wall.

Barry's Shop 177 by Bib Overalls, on Flickr

And then the forklift had to move around to the front and take another bite.

Barry's Shop 178 by Bib Overalls, on Flickr

The actual move took a couple of minutes and a little juggling to get spot on.

Barry's Shop 179 by Bib Overalls, on Flickr

The press was more difficult. The reason there are no "in the move" pictures is because my weight, along with that of five lead acid truck batteries was needed on the back of forklift to keep the steer wheels on the ground. Even so, the forklift was difficult to steer.

Barry's Shop 180 by Bib Overalls, on Flickr

In position next to the shear. Barry has a ten foot press brake but it only has one set of dies. He uses it for bending the stainless steel sheet metal that goes into the tanks he builds. This press can be fitted with special dies for forming, rather than simple bending.

Barry's Shop 181 by Bib Overalls, on Flickr

 

[Skyline]

The ingenuity of you guys is really inspiring. Thanks for posting.

 

[ADSR]

That press is huge!

 

[Bib Overalls]

That press is huge!

It has an 8' capacity and 36 tons of press. Big machinery like the lathe and press above generally sell cheap. There is almost no industrial demand and the cost of loading, rigging, and transporting can be intimidating. The lathe and press both had $100 loading fees added to the auction price. Fortunately, Barry has the equipment and knowledge to handle the transport and unloading by himself. For the kind of work Barry does the older machines are more than adequate.

 

[sean Buick 76]

What a crazy build!!!!!! WOW!!!!!!!!!!!!

 

[Bib Overalls]

Haven't posted any updates for a while. The reason is that Barry had to apply his time to money making projects and he could not work around the disruption changing shop buildings would create during the busiest part of his work year. So, the shop has set for several months with little progress to report.

That changed last week when Berry finally started moving his machinery out of the old shop.

In the first picture you can see his metal lathes. If you look carefully, you can see four.

Barry's Shop 182 by Bib Overalls, on Flickr

In the second picture you can see his mills. Again, he has four.

Barry's Shop 183 by Bib Overalls, on Flickr

He also has four drill heads, two on individual pedestals, and one double mounted to a heavy table.

Also coming, a large industrial blast cabinet, vertical and a horizontal band saws, a large buffer, 12" grinder, and a surface grinder.

All this in addition to a full welding shop as well.

What do you need? If it is made from steel, stainless steel or aluminum Barry is your man.

 

[403is300]

The things I could do with all those tools.... amazing!

 

[Big_Al650]

Just joined this forum yesterday. Great build thread. My favorite part is the manner in which the early criticism was handled which seemed to cause it to run and hide. I tend to avoid forums where negativity feeds on negativity.
Your resourcefulness amazes me. I can only imagine what it would have cost to have this done "turn key".
I have worked in the same general fab/welding shop for the past 20 years, I know what you can do with the equipment you have there along with some skill which you have already demonstrated you possess.

Subscribed.....Al

 

[1/2 Cup]

Just checking in again. Looking fantastic.