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Calgary double garage

dubcanuck1

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Jul 29, 2013
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Hi all,
I've been reading a lot of your threads and I figured I'd share the work I've done in my garage.

The skinny:
8 years ago, I moved from my old place, which had a 22x24 detached garage to a new house. This house had a double-attached garage that's 20x21. So needless to say, I was underwhelmed by the reduction in square footage, but hey, the house is a lot nicer, sooo lemons->lemonade sorta thing.

I'm struggling to find older pictures of the garage, but here's sort of where it started. It was uninsulated, and the most basic 2-car garage you could get. Staircase to the man door right in the middle.

Here's a pic of where it ended up after a couple years. I insulated it and put up some OSB on the walls, then, as the garage is 13' high, I built up 3 rows of overhead storage.
99GTI005-sm.jpg


The opposite side was essentially the same.
shelving01.jpg


At some point, I picked up a 4 post lift. This is actually a good pic of where things were as of last spring. As you can see, I used the sides of the staircase to build a workbench, and an overhead shelf/gangplank to the wall-mounted shelves.
shelvingAndLift01.jpg


A small digression, but here's what I did with my overhead door so that I could open the door with a car on the lift:
garageRails01.jpg


garageRails02.jpg


garageRails03.jpg


garageRails04.jpg


So that's where things started to bother me. I had a 20' wide garage, but due to the construction of the shelves, essentially only 16' was useable. If you look in the previous pictures, you'll notice that there's a lot of vertical 2x4 supports holding the shelving up as well as dedicated bench space (24" benches and shelves). This meant that when I was working on cars, I would have to do a lot of maneuvering to get around. That frustrated me, so I decided "hey self. You can weld. And you have an idea".

Here's how it started: I pulled down the shelves on one side and built steel shelf supports to hold up the shelves overhead, thereby freeing up the dedicated floor space that was occupied by the benches, etc...

shelving02.jpg


I'll let the images do the talking next (with a small preamble): The brackets are built out of 1x2 mild steel, 1-1/2" angle iron, and some 1x1" square tubing with some plate steel acting as the "foot".

The brackets have tabs on them that essentially held them briefly to the wall. I screwed the shelving in from the bottom of the angle iron bits and then the shelves get screwed to the wall, securing the brackets to the wall as well.

brackets01.jpg


brackets02.jpg


brackets03.jpg


brackets04.jpg


brackets05.jpg


brackets06.jpg


brackets07.jpg


brackets08.jpg


shelving03.jpg


shelving04.jpg


I was pleased with the outcome of that side and it's served me well. However, the other side was the real pain in my ****. I wanted to keep the dedicated bench concept that I setup in the pic below but make it, and the stairs out of steel, so that I could have a large under-bench space to store a few welding tables that are in the works.
shelvingAndLift01.jpg


So, of course, I had to tear the other side apart and deal with that. As I had to remove my staircase, I hummed and hawed until I came up with an idea, using some metal that I scored off of Kijiji (Canada's Craigslist). Long story short, they were metal walls made of 1x3 c-channel. I cut them apart and that's what I used as the material for my construction idea.

Quick pic of the metal walls (which took a lot of effort to get converted from the 1st picture's state to the second).

metalWalls01.jpg


metalWalls02.jpg


Plans:

plans01.jpg


plans02.jpg


plans03.jpg


plans04.jpg


plans05.jpg


Teardown and prep:

IMG_20160123_153921-sm.jpg


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The raw materials. Much cutting, grinding, welding and cussing was done getting these reduced to just the c-channel.

IMG_20160124_183528-sm.jpg


IMG_20160124_194752-sm.jpg


Progress:
My 15-year old who is likely a better weldor than I am.

stairs01.jpg


stairs02.jpg


stairs03.jpg


stairs04.jpg


stairs05.jpg


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stairs08.jpg


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stairs10.jpg


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How I connected the top railing to the vertical support of the stairs (left side)
IMG_20160310_200707-sm.jpg


IMG_20160310_231335-sm.jpg


This pic is great to highlight the "span" that I have under the platform. My welding table will be ~7' long and I'll have a welding cart at ~2-1/2' that both slide under there.
IMG_20160313_152858-sm.jpg


IMG_20160313_152942-sm.jpg


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Edit: The other side shelves. More of the same sorta stuff:
brackets20.jpg


brackets21.jpg


brackets22.jpg


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brackets24.jpg


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brackets26.jpg


brackets27.jpg


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Where it stood last I worked on it, before I fired a few cars into it.
stairs12.jpg


That brings us up to current.
 
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SiGmA_X

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You've got a lot of stuff in a small garage, nice work! Where does the engine hoist, bandsaw, and compressor go when everything is put away?
 

matt_i

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You are getting a lot of use from that MiG welder! Congrats on teaching your son to weld.

I can tell from your drawings, fitting things nicely into tight spaces, etc, that you are putting a lot of thought and planning into this workshop. Great way to maximize your storage space. :)
 
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dubcanuck1

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So, I'm currently building a 10x10' shed. That'll be the home for the engine hoist, and most of the spare engines that might be seen in some of the pics under the stairs platform. That, and anything really awkward, like my table saw, mitre saw, possibly even my drill press (still undecided on that one). For the engines, I'll be building a little trolley that I can quickly fit under the pallets that the engines sit on, then "jack up" so they can get rolled into the backyard and the shed.

The bandsaw is going to receive a lower-slung stand with some castors and its regular home is under the steps (the 45 degree part). I'm planning on putting some trailer receivers on my welding table and the bandsaw's frame will be compatible with those, so I can put down some long material and cut it on the saw with the material sitting on the welding table.

The compressor. Thank you for reminding me. That was another reason for the build. Working around that 3' "pill" can be frustrating. My plans are to split the compressor from the tank and mount the tank overhead on one my shelves, then, on another, lower shelf, I was going to create an isolator platform for just the compressor part that was a little bit closed off (for sound purposes) and plumb hardlines throughout the garage as well as from the compressor to the tank.

You've got a lot of stuff in a small garage, nice work! Where does the engine hoist, bandsaw, and compressor go when everything is put away?
 
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dubcanuck1

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OK. It's been a while. But I had to scrounge up materials for the shed and get that on track before I could make much more traction in the garage. The Coles' notes version is this:
10x10 shed. semi-vaulted ceiling (to keep the oboxious factor down). Inside will be OSB finished and I'll weld up a metal door and security cage on the window to keep the criminals thinking of other easier targets.

I got a 30x8' shed I had to dismantle from Kijiji (Craigslist for Canucks).

IMG_20160515_184626.jpg


1st base
IMG_20160514_170036.jpg


IMG_20160514_170316.jpg


2nd base (lots of cross-bracing as I'll be putting up to 7 engines in the shed).
IMG_20160514_211400.jpg


3/4 tongue and groove plywood.
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Working on the peaks. With hand-built vaulted bits, this was actually more work than you'd think.
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A view down the tunnel. I'll cut a gable end vent in each end.
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Getting the trusses sorted. Lotsa work here and more than a few adjustments.
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Sheathing on.
20160603_194102.jpg


Shingling in progress.
20160604_143013.jpg


Smallish Bear helping with the roofing.
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20160604_200213.jpg


....annnnnd what my shed is largely used for right now......
20160604_221501.jpg
 
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dubcanuck1

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Hmmmm. I just realized I forgot to upload an update. Oh well. Since the shed part is the "distraction", I'll keep it short.

20160710_104417-sm.jpg


20160710_150411-sm.jpg


Homemade door. Took some recycled plywood (3/4" on one side, 1/2" on the other side) and glued/sandwiched it around some 1x4. It's beefy at 2-1/4" thick. Enough so to require longer pins for the deadbolt.
20160807_181735-sm.jpg


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Anyways. Now that that's largely done, I can move the engines out from under my stairs and finish the garage shelves and start on my welding table and other schemes.
 
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dubcanuck1

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Thanks. I'm kinda proud of it. The money I spent on it is probably what a store-bought shed package would cost just for the shell, but it's built more like a house than a shed. And it's only 8' tall at the peak, so it's not obnoxious to my neighbours, who call it the "Guest House". It's fully insulated, so I'll be able to do stuff in it in the winter if needed. I've still got shelves to put into it (and paint) and also I have to run the surface-mount electrical and LED light strips for lighting.
 

dubber

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Just found your thread for the first time. Nice job thus far. What are the specs of your mk3? I used to have a 98 GTI VR6 in black that was a blast.
 
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dubcanuck1

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The black one was a 99 GTi-VR. Bored to 2.9L,268 cams, high lift springs, SAI delete, C2 chip for the cams and a bunch of aftermarket mounts and shifty bits with shaved hatch and Euro front/rear. It was a fun car. Probably should have kept it.

Just found your thread for the first time. Nice job thus far. What are the specs of your mk3? I used to have a 98 GTI VR6 in black that was a blast.
 
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dubcanuck1

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So, there was some Sleepy Hollow action that happened this evening...... Tomorrow it's going up on the shelf.

20160903_013530-sm.jpg
 
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dubcanuck1

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Sooo yeah. Today was a busy day. Most of it was spent getting the tank bit done.

What do you mean, this isn't covered under warranty?
20160903_132638-sm.jpg


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I sure wish I had this to take the thing all the way to the top where it ended up.
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No EH&S people were harmed, nor even remotely present in the locating of this compressor tank....
20160903_214329-sm.jpg


Now I'm going to have about 6 beers until my wazoo stops clenching and then get to welding some shelves.
 
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dubcanuck1

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OK. Apparently Labour Day weekend doesn't mean to labour all weekend. However, I'm feeling pretty good about the progress I've made.

I figured I'd show this part. I'll be putting a lever on that so this so that I can more easily drain the water.
20160903_232237.jpg


Middle Shelf
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Test fit
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Back out for some paint. This was by far, the easiest one to build and put in. Bu-leeee-dat!
20160904_125304.jpg

Fast forward a bit to the one shelf that will act as a "lift post lock". This was the second easiest one. Only moderate "R" moments.
20160905_133909.jpg


I'll be using some threaded rod to "sandwich" the sides and keep the post positioned. I'll also build a rack for the top that will keep it from sway back out of the "hole". It'll bolt into a spare hold on the top of the post.
20160905_133915.jpg


annnnd that brings us to the m*therf*cker. As you can see, the shelf is ~7' long, but has to go around a support beam, and tuck inside the garage rail. I had to move the lift to even have a hope of getting this guy in, and even then, it was a sumbitch. This one got test-fit and then promptly painted in place.
20160905_142812.jpg

You can see the "press fit" into the corner....AKA the paint and material missing from the wall.
20160905_142821.jpg

Some dings....they might only be 3/16" deep, but when you're muscling a 75 lb shelf overhead, they catch like an iceberg.
20160905_142825.jpg


Victory!
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Still more to do, but man, that's a giant leap forward.

Not my finest work on the welder. The metal was still dirty in a lot of places. I wanted to take it to get it sandblasted before starting, but funds were short, so I cleaned the outsides with an abrasive wheel (yes, it was tedious).
 
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s123

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Really like your work and how you utilize the space. I think I never would have thought of splitting the compressor the way you did. Nice move!
 
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dubcanuck1

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Thanks. The compressor in that configuration was a huge pain for a few reasons. 1. It's like a 2'x2'x6' hemorrhoid in the garage. You just always seem to need the space that it's consuming. 2. When the compressor is on the tank, it acts a lot like a sound chamber/speaker, making it a lot louder than it needs to be, especially if you don't have the isolator feet under it.

I'm going to take the flange for the motor and compressor and build an isolator pad with some old valve springs (think earthquake system for buildings on a smaller scale). This should let it shake a little bit and not transfer the momentum to the shelving and walls. Then, building some shrouding around it should help with the sound, so that it doesn't scare the sh*t out of me in the middle of the night when I'm working on something and it kicks on.
 

s123

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Really good ideas, I will probably replicate some of your ideas when it comes to install a compressor in my own garage. I prefer to listen to almost anything but my compressor when working...
 
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dubcanuck1

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So I got around to making the brakets to hold the lift posts in place. Once the other one is made, it'll all be held in place pretty well with some allowance for adjustability.

20160910_161040.jpg


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20160912_124151.jpg


20160912_124156.jpg
 
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dubcanuck1

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So, it's been a while. Work's been a bit nuts, and I had to help my mother move out of her house, which chewed up a bunch of time. I had to clear some room out of the garage to get things finished up, but here's a small update on the shelving, which is now done.

The middle shelf. Nothing exciting here. Just some notching.
20161116_154214-sm.jpg


The end shelf that was already done previously, as well as the bracket holding the lift post. This is where the compressor motor will go.
20161116_154242-sm.jpg


A shot of the bracket installed on the top of the post. I actually made this one a bit too short, so could only bolt it in with 2 bolts. If it bugs me enough, I'll refab a new one later.
20161116_154223-sm.jpg


.....and the last one installed and now the lift is more stable.
20161116_170221-sm.jpg


And what it gave me underneath.
20161116_182039.jpg


Here's a shot from the end of the shelving (top)
20161116_182001.jpg
 
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dubcanuck1

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Small update. Getting ready for the Christmas break to kick in so I can make more progress. I just picked up this little beauty the other day. Gonna be a warm winter.....

20161213_220638.jpg
 
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dubcanuck1

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OK. So, let's put up an update. I guess I was busy over the break after all.

Step 1: find the garage again. Sorta done, done enough to find stuff and to move around.
20161221_210845.jpg


Step 2: hang the heater...... done. Well, it was a little more involved than that, but that's rather boring.
20161229_122109.jpg


New welder arrived finally. Let the fun begin. MTS251.
20161229_121015.jpg
 
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dubcanuck1

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Step 3: Welding cart (elevated work platform). Man, I hate welding on concrete. I'll eventually add to this (eventually being in the next couple weeks), but priority 1 was just getting something to work on.

Details: I had cut apart several 42U (7' tall) server racks a while back. This is what I used for the base. But it was the wrong size, so I modified it.
The legs are 1-1/2" mild steel.
The top "C's" are 1"x3"
The top is 36"x36"@1/4" thick.

Pics or it didn't happen I guess:

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As mentioned earlier, I just needed to get the work surface going. on the list for additional mods:

  • slide-out bottle holder (for 2 bottles)
  • Upper shelf for welders to sit on.
  • Down-draft portion (including mag-drilling the 5/8" holes on a 45 degree angle (4" separation) and putting in the piping that'll hook up to my air scrubber (it's on the list)
  • "dust tray" under the top.
  • Lower storage drawers.
  • "stay put" system (either replacing the current casters or throw on some of those "step on" lifts at each corner
 
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dubcanuck1

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Step 4: The welding 'table'

Cutting, de-rusting, beveling, and general cuss-ery went on to get to the first pile of material.
20161231_203409.jpg


Best way to work off a New-Year's hangover. Weld some stuff (oh and Advil helps).
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Yes, I ran out of clamps.....
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Smallish Bear jumped in to help me with some of the welding. The quality of welds went down as the mercury did. It was pretty frosty in the garage with no real heat source yet.
20170102_215600.jpg


Quickly put on the casters.
20170102_231554.jpg


I'll be stealing the acme threaded rod/telescoping legs with locking casters idea at a later point so that I have some foot clearance under the office desk shelves that'll fill the center of the bench.
20170102_231642.jpg


......and the mag drill's going to get some work drilling holes in this: 36"x72"@3/4" thick
20170101_123258.jpg


Lots left to do for this table, but I figure I'll get that sorted by mid-January.
 
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dubcanuck1

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Well, I've had a few days of futility with not a lot of progress, but I think I'm on the verge now of making some headway. I put a divider into the table as I'm going to go with 2 rows of shelving (29" wide).

The divider. I'm going to drill some holes in the top center brace for the downdraft piping to route. I also decided I'm going to do the extendable legs and locking casters sooner than later, so I'll be picking that stuff up in the next few days.
20170108_162604.jpg


So, another bi-product of the server rack dismantling is that I've got the side-rails that house the cagenuts, which is what will hold my drawer slides.
20170108_100142.jpg


So, I cut them down to size and bolted the cross-member bits to them so I could do some measuring for the enclosure that will go around them. I plan on having 3 wide drawers per side with each drawer having a left and right side (an undivided 29"x29" drawer would end up being something like a woman's "big purse", which I just can't abide.
20170110_000134.jpg


Cage nuts installed. The drawers will sit on standard 28" server rails (I'll dig up a pic at some point).
20170110_000145.jpg
 
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dubcanuck1

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:D I should probably weigh it when I'm done, but I figure it'll be close to 1000 lbs "dry"
 
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dubcanuck1

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OK, so after 3 days of futility, fiddling with filing cabinet dismantling, messing about, and trying to make my "free" material work where it wasn't the best fit, I decided that my frustration was a problem that money could solve. I'll fiddle with the other super creative recycling projects later. Right now, I just have to get this part done, so I can work on other projects (which cause revenue, not expenses).

So, here we go. It was an expensive day:

Bunch of 1x1@1/8" square tubing, 1x1 angle iron, and 2x2@3/16" tubing.
20170111_183006.jpg


This little pile was particularly expensive. "All-stop casters (800 lb) and some 7/8" acme threaded rod.
20170111_183036.jpg
 

Knyte Tyne

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Heavy Duty Castors can be Pricey. I just bought 4 for my main work bench. Even though I don't intend for it to be HEAVY duty I've still got 250kg castors on each Corner. They look similar to yours. I'm super happy with them... They lock down like a Pissed off Pitbull and the Wide Contact Area on the wheels means it doesn't accidentally slip as I've had with thinner Castor Wheels. Bench is Awesome... Keen to see where your taking this. Very Clever Use of the Server Rack Parts... I've got some Awesome Massive Drawer Slides from an Old Poweredge Server that I'm hoping to use soon. The server itself weighs about 30kg and the Slides come all the way out... Should let me build some Nice Long Heavy Duty Drawers... as much as ive tried to build the whole thing from avaialable materials like you say sometimes you need a little money to solve the frustrations. I'm almost in the same amount it would cost me for an al'Cheapo Tool Trolley - But then I wouldn't have a bench to work on... I'm happy with the outcome.
 
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dubcanuck1

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Yeah. These rails came from some old Compaq server kits. They're stout. I wish I could have gotten the ones that they used when I first started in IT that held the 5-U servers (they were HEEEEAVVVVYYY).

As a later project, I'm going to build a massive shelf in the "cubby hole" in my staircase (if you look close, you'll see an opening right under the foot platform. For that, I'll use 2 rows of rails, and also because I want the slide to come out 36", I'll be combining multiple rails to get the amount of extension I want. It's amazing how much metal I still have lying around from those server racks.
 
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dubcanuck1

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OK, so I did make some progress over the weekend. Pics do most of the talking again.

Bandsaw did its whittling....
20170113_175341.jpg


And the "cartridge"
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Fitted into the rest of the table.
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Some paint:
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Fun tapping
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The opposite of fun tapping (folks, just buy HS taps. The savings in the swear jar will be worth it!)
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Where we stand today:
20170116_235549.jpg


I'll get back to it this weekend, when I muck about with the extensible legs, but I get to also fiddle with hacking/combining a bunch of drawers together. I think it's going to be 3-5" drawers and a 3" drawer on the top (mirrored on each side of the cartridge).
 
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dubcanuck1

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So, I had to use the garage for something other than making stuff (like fixing a car), so I had to put the top on the table last night so it would be out of the way. Here's a closer idea of what it'll look like all done. Just image 5/8" holes in the top and drawers in the middle.

20170121_015707[1].jpg
 
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dubcanuck1

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So, having to do work on car stuff forced my hand a little bit on the compressor project. So, here's the progress there.

I didn't know how well this would work out, but I had some old VW VR6 valve springs kicking around and this idea in my head for an isolator stand. I used some 2x4 as well. If this works, I might replace it, or just wait until the springs wear through the 2x4s and then I'll replace things.

The start
20170211_134420.jpg


Super scientific method of depth gauging. Drill some, then some more, then measure, then drill some more.
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And an idea of the way it'll be built.
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Thank you VW!
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Put together
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Test fitment and marking of where I had to butcher.....I mean finess holes into the top platform.
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The end of it all.
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Up on the shelf. It's a heavy mofo.
20170211_165738.jpg


So, now that that was started, I got working on the piping to connect the 2. This took many trips to the hardware store for pipe, elbows, fittings, compression fittings, this, that, $&%&%$*&#&@&@&@
20170219_093802.jpg


Side exit. I used 1/2" black pipe to connect the tank and the compressor.
20170219_093810.jpg


How they route into the shelf.
20170219_095734.jpg
 
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dubcanuck1

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Apologies for the lack of progress. Change of llans in life. Couldn't refinance the house due to the divorce, so after some scrambling around this and that financial hurdle, I'll be finishing up a few projects like the table and the compressor, then will be building a home on an acreage (complete with a 60x50 "attached" garage and work rooms).

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dubcanuck1

Active member
Joined
Jul 29, 2013
Messages
42
Well, it happened. Had to sell the house, so I grabbed some video of the stuff in the garage before its gone forever.

There's still a few things I'm goimg to finish off (on principal) so I'll probably snap a bunch of pics and some video of that as well.
 
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