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Above 1200 Sq/FT Eastern Washington Workshop

Wokspaces above 1200 squarefeet.

loganb

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This point is probably worthy of it's own thread!

Great point and agree it could be a great stand alone thread topic as everyone has a different viewpoint on their mental math on where they spend money.

Earlier on in my professional tenure post college, I was often too prone to try and find locally available solutions or order a product available from multiple sources from a more local vendor/local branch location at the sacrifice of speed(and likely cost but speed was more important). When I saw the $ value of bills paid for general day to day supplies and local services(local was within 20 miles radius) to keep a 350 to 400 person plant operating over the prior 12 months it was a large enough number that changed the perspective. Time and our engineering team resources were our bigger constraints, so if there was a viable local solution that didn't sacrifice the solution/implementation timing we'd go with it. If that local solution was going to significantly impact implementation or resources we would normally move to that non-local source. If it was ordered on McMaster by about 1pm and in stock in Chicago, it was on our dock generally by lunch the next day...if it came from the Jersey warehouse it showed up around 4:30. Solve it and move on. This is specifically to expensed build items/minor changes/repairs etc, if it was a capitalized purchase the rules change.

Personally I'm too fast to buy various pieces/parts "cause it's a great deal" and try and put something together cause I'm not valuing my time high enough and the resulting project takes far too long and could've bought the complete product and been using it for months now...case in point the dust collection project. Fasteners basically all come from McMaster or local hardware store as Fastenal now acts like a private club and without a business account you don't get in, but the solenoid valves for my blast gates were 7x more at McMaster....better product but for my application the cheaper version was closer to what I needed. I bought a garage door opener today on Prime Day as the local distributor wouldn't sell the opener alone to me and their installed price was 2.5x my cost of the opener...but will likely pay one of their guys to install it. I would've preferred to pay the local people vs Amazon, but the premium was too much to justify in my head. I'm trying to be more intentional with who the money is going to and try to lead with local first when viable, just doesn't always work out. I think this mindset is fairly pervasive across GJ, but we all have our own "weighting" of what's most important which makes it interesting

But that's enough side tracking of your thread...back to more cool custom fabrication stuff or where ever else you're willing to take us!
 
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slodat

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Good stuff, Logan! I'm similarly minded personally. As the business evolves, I see my decision making evolve. I am of the opinion that time is the most precious resource. Take a look at Automation Direct for the pneumatics. I buy a lot of my air system stuff from them. The main header pressure regulator is coming from them today. I have not had a failure of any of the pneumatic stuff I've bought from them. I did get the 5 way valves from them.
 

lilscorpion

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We settled on using the pallet jack for moving whenever the need arises. Shouldn't be too often and the pallet jack is perfect for it.

And, I lowered the lower cross members so the pallet jack can lift the whole thing.

That’s a good idea. Haven’t been thinking like that but I’m gonna add it to my thought process for design.
 
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slodat

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The air filtration loop turned out nice.
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Cut the parts for the conveyor. The advanced arrange in Fusion is really working well for me.
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This was a fun photo.
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Now for something REALLY satisfying! The bottom of the legs turned out great!
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And the money shot!
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I am thrilled with how it turned out! Then I bolted everything together to check fitment.

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Next up is blowing it all apart, powder coating, and final assembly.
 

zanyad

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Now for something REALLY satisfying! The bottom of the legs turned out great!
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And the money shot!
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Woooow!!! :rocker:
 
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slodat

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That’s a good idea. Haven’t been thinking like that but I’m gonna add it to my thought process for design.

Everything in my shop from machine tools to benches, tables, and toolboxes was designed to be easily moved with a pallet jack. Once you do that you'll wonder how you ever did without it.

Using a pallet jack to move things around the shop is a great solution. Most of the time casters are a pain in the ***. I much prefer leveling feet. I’ll readily admit I often don’t think of it when making stuff for the shop. I’m glad I thought of it in time on this one.
 
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slodat

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When the rest of the rollers arrived I set them in place to make sure all is well.
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I spent the day working on the conveyor. The weld nuts dropped in place on the bottom of the legs.
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Once the legs were all welded up, I sandblasted and got to powder coating. The powder coating turned out great. Powder is a satin black from Columbia.
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I'm really liking cutting the drops with the parts. Makes for quick work of clearing that table for the next job.
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The shelf and dust tray were at the ragged edge of what will fit in the oven.
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Final assembly was all that remained. I used a square to make sure the lower frame was squared up.
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Once the dust tray was cooled down, I sat it in place and finished assembly. This project was really satisfying. All the fasteners dropped into place. Even when it was three parts stacked up.
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A shot of the assembled frame with everything tight.
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And, with the rollers in place.
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Considering it's intended use, it won't be this pretty very often. It will be nice to have it on the outfeed of the sander. A really enjoyable project.
 
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slodat

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Thanks guys! I appreciate the words of support. Generally speaking I doubt there’s much demand at the price I’d need to charge for it to make sense to market, design, manufacture, powder coat, package, and ship custom shop carts. While the sentiment is nice, purchase orders are what drive my business. if anyone wants a custom cart, I’m happy to work with you ;)
 
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slodat

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Worked on some shipping case foam for a client this week. This is the photo they sent:
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This is how it arrived:
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My design:
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The green component is a 3d printed bin to hold the power supply pouches. My thinking is a 3d printed bin will keep the foam from getting chewed up by the laptop power supplies.

IMG_6721.jpeg

It's quite big, and I wanted it to be strong. 1/8" wall thickness should do the trick. The PETG should hold up well. The XL continues to make really nice parts. Just slow compared to the X1C. This thing turned out nice.
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Assembled:
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This should hold the laptops securely and give a lot of miles of service. Next up was foam for a kit they make.
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The foam work is fun and satisfying. It takes some time getting the design sorted out and sliced in to layers. I'm really happy with the end result.
 
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slodat

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Ran some sheet metal parts and had a chance to try out the out feed conveyor. It works great. Plan all along was to sort out an end stop that’s easily removed.

This clamp has an anti-rotation feature built in. Slides over the last roller and has a small feature to hold the stop plate.

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In place.
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Powder coated and ready for use.

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This worked out well. Easy to remove when running really long parts. The 3d printed bracket is really satisfying.

Air system is up and running. I already love having pressure gauge on the column. See it right when you walk in the shop.

IMG_6785.jpeg
 
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slodat

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Finally got the Sumo enclosure installed on the Prusa XL. Very happy with the enclosure. Very well thought out, went together well, and does the job nicely.

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I had some ABS auto interior parts to run for a buddy of mine. Needed the enclosure for the ABS. The XL did not disappoint. Parts turned out great!

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I was surprised to see enclosure temperatures up over 100F.

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The final parts. Door grills with trim rings.
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Continuing to work on the custom shipping case foam. These are fun, and the process is improving with each new design.

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slodat

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I started this big order of galvanized enclosures earlier this year. Then the client put the order on hold. Thankful to say we’re through cutting all 80 sheets of 16ga galvanized. That’s a big order for my shop.

Here are some getting close to ready to ship. This is a very satisfying photo for me. A lot of work and progress toward professional results and better processes and workflows. PLENTY of room for improvement! Proud of where we are nonetheless.

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Those were moved outside so we could get Building 2 ready for new machine day. Here’s a couple of shots after the prep efforts.

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The driver called from the shipping dock asking if he could deliver Sunday. The guys were great and came in on their day off to get it done.

The curtain side trailer was nice to see. That old Monarch lathe looks to be in nice shape.

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First up was getting the oven unloaded. I bought some $200 8’ fork extensions off Amazon awhile back just for this. They did a great job.

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When I ordered the oven I specifically asked for it to be able to fit in the 94” door tall opening. I knew it would be tight.

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30kw heating element and a legit blower setup.

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Removable fork pockets on top for lifting off the crate. They worked great.

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The door is incredibly well designed and executed. Very happy with the door and overall structural design.
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PLC controlled with an HMI.

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slodat

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We got it in front of the next door over and picked it off the shipping crate. Then I backed up to get it in front of the middle door.
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From there I wiggled close to the building and hooked the end into the door opening.
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This worked well. It was tiiiight.
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As they say… clearance is clearance, Clarence. From there we used two pallet jackets to move the rest of the way inside and into position.

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We lined it up on the post to get it as far to that end of the building as possible.

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All in all it went into the building and into position about as well as a guy could hope. Some planning sure helped. I had four solid months to work through it in my head. It’s important to remember when this was ordered, I was still painting the basement.

Initial observations of the oven are very good. The construction appears to have made for a very solid assembly. The floor isn’t very flat. Looking at what, if anything, will need to be done beyond some shims. I’m calling the manufacturer tomorrow to discuss their recommendations.
 
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slodat

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I needed to uncrate things to look for anything that may be damaged, missing, etc.

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These light fixtures seem to be okay despite the bent boxes. Once I started removing the booth panels from the crate I was quickly filling up the shop with them.

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So I started assembly. I like how they do these. They go together well and the design isn’t frustrating to work with.

Start with the upper and lower channel attaching to side wall panels. Then add the back wall.

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The chair ended up being my tool cart for the afternoon. From there it goes as quickly as a few hundred bolt/nut pairs go.

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Manufacturer shipped a regular roof panel instead of a second light panel. Save for that the main structure is together.

There’s a small aisle behind both. Plenty big enough for the ladder. (That’s how I assembled it.)

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And a small aisle between the booth and oven. The blower assembly hangs off the side. Because this is powder only and no paint, the blower can exhaust inside. There’s a three stage filtration setup to trap the powder.

The front plane of the booth sits a bit in from the oven.

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This should work well for us. Of course a bigger building would be better. For now, we will continue to work with the space we have. It’s nice to have the last of this stuff in place. I started the process beginning of April ordering the equipment.
 

RickP

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Jan 15, 2013
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Location
Annapolis, MD
Those were moved outside so we could get Building 2 ready for new machine day. Here’s a couple of shots after the prep efforts.

IMG_7154.jpeg
I'm always impressed by new machine day -- you've put together the infrastructure and machines to make it look easy.

New oven and booth look good, and I'm sure you've got enough work to put them to use right away!
 

lilscorpion

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Mar 15, 2010
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Location
Colorado
Ran some sheet metal parts and had a chance to try out the out feed conveyor. It works great. Plan all along was to sort out an end stop that’s easily removed.

This clamp has an anti-rotation feature built in. Slides over the last roller and has a small feature to hold the stop plate.

IMG_6751.jpeg

In place.
IMG_6752.jpeg

IMG_6753.jpeg

IMG_6756.jpeg

IMG_6754.jpeg

Powder coated and ready for use.

IMG_6755.jpeg

This worked out well. Easy to remove when running really long parts. The 3d printed bracket is really satisfying.

Air system is up and running. I already love having pressure gauge on the column. See it right when you walk in the shop.

IMG_6785.jpeg
Roller stoppers, a neat idea!
 

Jdsmith

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Nov 24, 2012
Messages
42
Location
Ohio
I was following your thread a few years ago, up to where you had the Nova in the shop for upholstery work, and I’ve been off GJ since then because it was costing me too much money 😂. Just logged back on in the last few days and caught up with all of the changes in your life and your shop. You are climbing the learning curve quickly, clearly due to a lot of hard work and persistence!

You have a really fun niche too that I would love to be in once I get bored of the corporate world. I’m in the electrical industry as well, having worked in field service for a major OEM as well as a couple of large industrial end users in various roles. There is definitely a shortage of folks doing the type of work you are into. We have a great bus fabricator in Ohio that we have used for decades - I think he was one of the first onsite fabricators to set up a machine shop in a van and a bus fab trailer with the bender and ironworker. For sheet metal though we have just used local sheet metal shops, which is fine if you just need a plate with a hole and a few studs for a relay replacement, but for the switchgear mods and replacement doors and such that you are making it is critical to have someone with industry context doing the fabrication.

The paint color that didn’t match a few pages back on the Square D board was probably ANSI 70 grey - I think Magneblast was also ANSI 70 instead of the modern standard ANSI 61.

I’m guessing your direct customers are primarily field service companies, with some contractors and panel shops mixed in? My company has a refinery over on the wet side of the state, I’m curious what the best channel to get to you is if we need some help.
 
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slodat

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I last left off having started assembling the powder application booth.. The guys came in that Monday morning and we got to looking it over..

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In my minds eye I had always pictured a flow from left to right in the shop.. That almost works. The oven was moved to the left of the booth to accommodate the oven door. Otherwise we would have to swing ALLL the way around the open door with the parts on racks. This will flow better. It also gave a place for the blower and final filter box on the right.

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Speaking of the blower and final filter assembly.. It hangs midway up that panel..

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There are reinforcement hat channels bolted above and below the blower. It still sags a lot:

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While I'm overall happy with the manufacturer and the end product, this is a dumb move in my eyes. Enter this morning's side project:

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I thought this Fusion sketch was kind of fun. For those of you that use Fusion, it's fully constrained as well ;)

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The bottom will be welded to the side flanges. This will both level and support the fan. We all agreed this was a must have. The funny thing was I already had the leveling foot. When I bought them for the CNC Hardinge I bought four not knowing the lathe had three leveling foot locations. Made leveling that lathe easy. Now the loose leveling foot gets put into service.

Building 2 is taking shape. I need to get the powder coating up and running in in the next few weeks for an upcoming project. I'm on the fence if we move the smaller oven to Bldg 2. Time will tell. I took a few wide-angle photos with the proper camera. Nothing like a real lens!

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Quite a bit of work still ahead, but we are making progress.
 
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slodat

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It took some doing, but I managed to get the new oven up and running.
IMG_7486.jpeg

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Its design limit is under 100 amps 240v single phase. The 30kw heater unit has a max usage of 75% in the PLC program.
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This is how the current is limited. I’m happy with the oven’s PLC controls.
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The floor is not level. At all. Not shocking to me either. Old building with a basement in the area the oven sits. We shimmed it level and grouted it in.
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This worked really well. The first time I heated it up the door opening taco’d open enough to be a problem. That’s when we realized the door frame needed to be anchored as well. If was easy enough to get it all square once it cooled down. After the anchors were installed, it went really well.

Oven takes about 30 minutes from 70F up to 400F. It’s insulated really well. It’s barely warm to the touch on a lot of the exterior. The recovery from opening the door seems quite fast. I’m happy with the oven at this point.

I’ve needed a place to put my project car until I have time for hobby stuff. I found a nice, big storage unit. Got the car and a few things moved yesterday. Now Building 2 is empty of any and everything that doesn’t belong.

Next up is the application booth.

It has become quite apparent that I need an office. Up to now I’ve been in the same spot in the middle of the main shop. Makes it hard to focus. We emptied the front room and moved in some office furniture I picked up used.

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It’s a bit small, and it will work well.
 
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slodat

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Steven, small is good, especially if you don't have to entertain clients in it. It's also economical to heat/cool.
Bob- good points for sure. The office sees direct sunlight the first half of the day. It’s rather brutal in the summer. That’s why I have the black PVC sheet hanging over the windows right now. I’m still trying to decide what sort of blackout shades I want to get.

I did move my computer in to the office. It’s going to work out well.

IMG_7494.jpeg

Definitely going to take some getting used to.
 
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slodat

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Steven, for your windows, you might want to look at adding some window tint. I have used this stuff on the last four homes we have had and swear by it. I have only seen it sold at HD or online.

Here's the link, https://www.homedepot.com/p/Gila-36-in-x-180-in-Titanium-Heat-Control-Window-Film-HRT361/100616385

:beer:
Dan - thank you for the recommendation. These windows already have a film on them. There's no avoiding a glare in the office room. I'm looking at which blackout blinds I want. Leaning toward cellular blinds. For now, my scabbed over 1/8" black PVC sheet gets the job done until I get something more presentable. Working in the office for a few today. It is growing on me as I get things setup.
 

rvieceli

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Nov 3, 2013
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Illinois
Steven that office looks great. Most big offices mean more space for piles of ****. Smaller means you’ll be forced to deal with stuff and put it away. Added benefit is that most of what you may need is just a short roll on an office chair away.

Ron
 
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slodat

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I made a return for the desk out of some stuff I had lying around. Two layers of mdf that was once the spoilboard on the router, topped with black laminate, and the edge coated with the Marsh spray ink. All in took less than an hour.

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I’ve always liked the desk drawer trays that ride on the rails formed from the steel drawer sides. I designed a couple and printed on the Prusa XL. The most recent is particularly satisfying..

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Now the calipers, loup, and tape measure stay put!
 
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