Mopar / Wood Shop Cave

[drivesitfar]

MF: i've never been to Florida, but Universal Studios in Orlando is on our so called BUCKET LIST cause we really liked our time at Universal's Hollywood, California theme park we spent a day at last year.

sounds like you had fun and since your kids are fairly young I'm happy to hear you (and they) survived.

 

[shortykorte]

Glad you had a good trip to Orlando. Hopefully the lines weren’t real bad (as in 2hrs). Definitely a lot to see and do.


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[moparfreak]

Got up somewhat early (for a sunday) today and made some great progress on the welding cart with my SFIL. First got all the pieces cut. My first time with a cold saw, really nice. Makes super clean cuts, much better than the abrasive chop saw I usually use for cutting up steel like this.

Got the miters prepped for the base which is made out of 1x2 tube which is just what was around and available (i.e. cheap!).

Then I got my Lincoln SP135 which is a nice basic but quality MIG welder setup after sitting dormant for years. Had to switch out a cracked O-ring, but otherwise got it hooked up to SFIL's Ar/CO2 mix and it was welding & fitting really nicely, which I was impressed considering it was sitting in a woodworking shop collecting dust for so long. This is probably my first weld in at least 5 years since before I moved & started up the house & shop projects...not as shabby as I thought it would turn out!

Nothing a little grinding won't fix. My SFIL told me his welding instructor from back on the AF base told him welders are much like undertakers, cause they can bury their mistakes....lol.

Moving on to welding up the rest of the pieces...

That's as far as I got today, I took the rest of the pieces home along w/ the gas tank so I'll get things setup in my shop to get the rest of this put together, so hoping I can get it done by this time next week (if I'm lucky...)

 

[moparfreak]

Took a little break to finish up the 3/8" drive socket drawer w/ the foam inserts. I think it came out pretty good.

 

[moparfreak]

Hoping to make some progress in the shop today, getting geared up for my winter break coming up soon, so I gotta get the welder cart finished along with the attic modifications for storage of the Charger parts.

In the meantime, got this haul from my SFIL for hanukah, nice Incra stuff!

Also, I had my third tire inflator fail on me so I decided to take some advice from GJ (again) and ordered in the Astro inflator that everyone on here seems very very happy w/. This is after going through inflators from Husky (HD), HF & Kobalt (Lowes). All failed in the seals or something internal. Hoping this Astro one lasts a good long while. It certainly works nicely and looks good!

 

[moparfreak]

Got to working a bit on a little framing job, as a setup for the work I'm beginning on the Charger. I have a lot of attic space over the 2-car garage portion of the shop that I plan to use as a space to dump a lot of the parts that I remove from the car while it's being restored (dash, seats, interior, glass, drivetrain, suspension, steering, trans even, pretty much anything I can fit up there except engine itself).

In order to do that I need to frame out an opening to pass through. The original roof rafters are there on 16" centers to make it quite a twist to get through there.

So, first step is starting to cut away some of the remaining panel sheathing to get ready for framing.

Working up there in closed confines isn't awfully pleasant I'll admit. Even making simple cuts is quite challenging, mainly due to space constraints. I have an M12 jigsaw and M18 hackzall that both make the job doable but even for those smaller tools I run out of space quick and had to do some hand sawing as well. Also encountered about 1 sqft. worth of old wasp nests embedded into the old roof vent. Yikes.

Here it is ready for the new framing pieces. Going to cut out the two middle rafters up to the cut and then box it in w/ new 2x12s.

 

[shortykorte]

So you have to frame out the upper and lower members? Or cut back upper frame member so you can make a hole in the
lower members.


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[sublime68charger]

Making nice progress!

 

[moparfreak]

So you have to frame out the upper and lower members? Or cut back upper frame member so you can make a hole in the
lower members.


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I'm gonna cut out the two middle rafters, and sister to the outers and put a header across, thus opening up about a 48" wide opening, while also transferring whatever load the two inner ones were carrying.

There's plenty of structure around it so I'm not too worried about it, just need to open up all that real estate. I've got about 25' x 25' worth of attic space there sitting dormant, which would be perfect for putting all the big weird shaped charger parts on. Really the only thing I plan to keep down on the main level of the shop is the body itself, the engine, and possibly the rear axle if it seems too heavy & awkward to get upstairs. I do have a chain hoist set up on the upper rafters in the attic to be able to slowly & safely lift up heavier items.

if all goes well I hope to do this framing tonight. Got holiday shutdown starting this weekend till the 2nd so I want to spend as much of that time working on the charger.

 

[shortykorte]

I created a 20x24’ loft for the same purpose. It’s full .....of everything but car parts for a restoration


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[moparfreak]

Well on Thursday and Friday I spent some more time up there and finished up the framing. It's complete and now I have a little through-way to get parts to the open space back there. Overall I'm pleased, maybe should have gone a couple inches higher but it's all good I think most parts will be able to fit through there. Adds lots of functional storage space for now and the future. I'll need to grab scrap sheet goods whenever possible and rip them down to get more floorboards up there to cover the exposed studs and insulation.

Also did a few more socket storage holders with the foam. First I finished up my adapters/u-joints/swivels. And yes I probably have too many of them...

Then I did one for a pass-thru socket set I had from Kobalt. This one worked out well, I used some existing holders rather than rout out the form for each socket, and it worked out. Also routed out a slot for the ratchet with some fingerholds and that worked well too, which I'll be repeating soon on the ratchet drawer.

Today I'll be focusing on completing the welding cart, changing the tires on my van to winter and a few other odds and ends.

 

[moparfreak]

Good day in the shop today. Got the family van switched over to winter tires finally (thank you quickjack!). Been lucky we haven't had a big snowstorm yet. Then got back to working on the welding cart.

Here's the frame pretty much all welded and after grinding. The shelf surfaces are 1/4" aluminum plate, which is just what my SFIL had around, as this whole cart is constructed with materials from the scrap bin. Made some notches to get the bottom plate in, and the top is just a simple square, but the middle shelf I welded myself into a corner as the piece I had cut doesn't fit into the opening...


So the solution, if unsightly, is to just split the shelf down the middle. I don't think it affects strength much, this shelf is meant for holding rods / spools, and some odds and ends tools and clamps. So for aluminum cutting I use this blade from an old 6-1/2" circular saw that I don't have anymore, but kept the odds n' ends blades. This one is nice cause it has zero rake angle, so it doesn't grab or bite too bad. I put wax on the cut line and a slow careful feed and it works great on the TS for straight rip and cross cuts.





I also recommend a face shield as it flings aluminum chips everywhere forward of the cut rather than down into the cabinet.

Here's how it looks for now, all I need to do tomorrow is drill and screw down the aluminum plate, add casters, and then also add a couple hooks for the cables and gun and then it should be ready to fill up. Then the Charger is next!

 

[shortykorte]

Hope you have a Merry Christmas.

 

[moparfreak]

Thanks Shorty and merry christmas to you too.

Still got a little bit closer on the cart today, in and around a bunch of errands w/ the family...

Drill & tapping holes for the casters.

Got it turned around and it's nice and mobile now. Despite being rather heavy it moves pretty well, which is good as I plan to roll it over to the car or the workbenches often.

Now the fun part, time to start filling it up.

I threw a bunch of stuff quick cause it was late but I plan to add some more small accessories to collect up the odds and ends such as clamps, cords, etc. to make things a bit more functional. But it's close.

 

[moparfreak]

Put the final touches on the welding cart today. I spent most of my time today just cleaning it up, loading it with all my weld supplies and consumables, and also adding in details for accessories, such as a magnetic strip, clamp storage and hooks for the grounding cable & MIG gun.

Here's the final piece, I think it turned out rather well, and fits just right in the spot near the car. For now I'll keep the abrasive chop saw but in the future if I choose to add another unit such as a TIG or a plasma cutter or a bigger multi-purpose welder it's got room for a second piece, along with a second bottle.

After dinner I took a bit of time, cleaned up the mess from the cart project and "officially" started the dismantling phase of the Charger restomod project. Took a few bits of trim off and started some work on the front clip but tomorrow I'll be putting it up on the Quickjack which I think will make some of that work much easier. Feels good to finally get that started.

Happy holidays!

 

[moparfreak]

Finished up the 1/2" socket drawer. All the sockets are done finally!

Over the next few days I'll turn my attention to the top drawer where I keep the sockets and extensions. It's a mess at the moment, but I'll start playing around w/ a few diff layouts and see what seems to work well and be efficient for space.

In other good news, got the Charger up on the lift and started the teardown process.

 

[shortykorte]

Cart came out nice. Seems to be missing some Plum Crazy or Go Mango though.


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[moparfreak]

Been focusing on the Charger, sloooow but progress at least...

Next shop project going on is to get this electric HF hoist mounted up on the ceiling header above the Charger bay. I plan to use it for light to medium duty lifting tasks, such as lifting machines up to do service, maybe lift the body shell a bit for repositioning, etc.

I've decided to fabricate a large steel U-bracket that will straddle the header, then use big 1/2" thru bolts to fasten in place, none of this lag business. This is constructed of 1/4" plate.

Since I don't have any tools predisposed to making nice quick straight cuts in thick steel stock (such as metal bandsaw or metal cutting circ saw or plasma cutter, etc), I resort to the strategy of using some angle clamped to the cut line and following it with a grinder.

Then once it's decently scored, it's easier to remove the guide and finish off the cut with the grinder.

Works well enough, operator dependent of course. One advantage here is all I need to do here is split the plate, I'll be using the factory cut edges to join up to the other pieces.

Next step is to prepare for drilling the holes. To make sure the holes are aligned, I get the welder out and tack the plates together. This way they can be drilled as one piece then I'll grind off the tacks.

Here's the header it's going on. It's 4-3/4" wide, and it's an engineered LVL beam, solid all the way through. Very stout and capable to handle some light anchoring / lifting loads. If it was just 2x10 or 2x12 I'd leave it alone but with the extra thick and deep LVL I feel quite comfortable. It's going to mount right in the middle over the car bay.

 

[larry4406]

I think I would be thinking gantry crane vs fixed mount location at this point.

 

[dusterbd13]

Im loving this.

 

[moparfreak]

I think I would be thinking gantry crane vs fixed mount location at this point.

Just not enough maneuvering room to keep a gantry around for the legs to support it. Same reason I abandoned the Maxjaxx type lift, as even though technically I had room on the two sides of the car for the posts, it would have made it impossible to get around on a daily basis.

I suppose I do a good job of keeping it stuffed to the gills, between the wood shop, daily drivers and Charger...

My SFIL has a sweet homemade gantry he uses and keeps outside for loading big machines and other things onto and off of a trailer. It's crazy, that thing can lift a 3,000 pound lathe (17" swing!!).

 

[shortykorte]

My HF winch and Little crane has been great for light to medium loads. Works great for a third hand for handling bulky or heavy stuff safely.


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[larry4406]

Just not enough maneuvering room to keep a gantry around for the legs to support it. Same reason I abandoned the Maxjaxx type lift, as even though technically I had room on the two sides of the car for the posts, it would have made it impossible to get around on a daily basis.

I suppose I do a good job of keeping it stuffed to the gills, between the wood shop, daily drivers and Charger...

My SFIL has a sweet homemade gantry he uses and keeps outside for loading big machines and other things onto and off of a trailer. It's crazy, that thing can lift a 3,000 pound lathe (17" swing!!).

I meant being able to slide the hoist left/right along the beam length but if it works for you fixed in the center then go for it!

 

[moparfreak]

Larry,

OK now I see your point. Yeah, a slider would be nice feature.

Decided to finally finish up the socket and ratchet storage, so here's the finished product, I'm quite happy, especially right in time for all the teardown work on the charger, makes finding stuff and putting it back away real easy.

Ratchet & extensions drawer:


1/4" drive, adapters, u-joints & specialty / bit sockets:


3/8" drive & pass-thru sets:


1/2" drive:


Breaker bars for each goes in their respective drive. SAE on the left and metric on the right.

Some shots of the whole cabinet & topper, including wrenches and other assorted stuff:






Long handle wrenches along with some room to grow:


Also keep miscellanous stuff, overflow sockets & wrenches, stud puller, tap sockets, etc in the cabinet above. Also have a few generic socket sets that are in enclosed cases that I can grab on the go if I need to have an assortment portable.





Time to close the book on this one. Back to the car and the hoist mounting bracket this weekend...

 

[1/2 Cup]

moparfreak great work on the storage..

 

[moparfreak]

Well I got distracted again, got this in the mail:





A few months back I took my 13" Craftsman planer apart that had badly worn down knives and decided I wanted to pursue a helical cutterhead for it. I got in touch with the folks at Shelix and though they didn't have that particular cutterhead for sale, they can make them to order if you give them specs. They'll even guarantee fitment if you send in your old cutterhead for them to have and measure during the process, which is what I did. So, finally got it back, and started putting the cutterhead back together:





I'm realizing I didn't take such good pictures of the planer when I took it apart, so hopefully assembly of the cutterhead back into it goes OK....

 

[e-tek]

How did I miss this?!? Awesome thread!

 

[moparfreak]

Thanks e-tek!

Well made some modest progress today on a few of these side projects. Mainly comes from my desire to clear off some workbenches where this stuff's been sitting for months...

On the planer, got the cutterhead installed. Press-fit isn't too crazy here so a deadblow and some careful alignment generally takes care of it.

Reassemble the gearbox that runs the infeed & outfeed rollers.

And back in it goes.

Decided to take a break on that and then turn my attention to getting the Electric Hoist mounting bracket made up so that I can maybe (optimistically) get it installed before the end of the weekend.

Drilled my pilot holes, then set up the bigger bit. I have it set at 5/8" hole and I'll be using 1/2" bolts, gives me a bit of slop as I'm worried about missing the hole on the other side when I use the big auger bit since I'll have to be drilling that with just a big handheld drill, so 90 maybe not be perfect.

I like to use the big floorstanding drill press but annoyingly the chuck doesn't quite fit 1/2" shaft which is strange to me, I'll have to change that eventually.

So I switch to the benchtop one which I use more for wood and soft materials, I got the holes drilled but this one has a lot of belt slippage, I'll have to change the belt out and hope that fixes...

Next I've got to mark the bolt hole pattern on the Hoist plate to drill into the bottom plate of the bracket. This one's a bit tough cause I don't want to disassemble the hoist, and also would prefer not to do it off of measurements. So, this calls for a little trick I learned when working in the machine shop in college, using these little threaded transfer punch deals. Not quite sure what they are actually called. You thread them into the holes then hammer the plate onto them, and they make your marks.

Next to help keep everything in alignment and solid during welding, I ripped a piece of lumber do the right width and drilled the 5/8" holes at the right pattern.

Then use bolts to put it together and it makes quite easy to get everything ready for welding.

Got it tacked in place but then had to run inside, hope to get this welded and ground down tomorrow, and maybe get set up to install on that header. It'll be nice to have lifting capability for heavy things.

 

[moparfreak]

OK so I wanted to get this hoist thing done and behind me...got the bracket welded up this morning & ground down flush...(pardon the newbie welding job)

Fastened to the hoist itself...

THen had to put the tires back on the charger, set it down and roll it backwards to get clear access to the install area of the header. A ladder and "lab jack" gets it up and into position. I also drilled small holes in the corners so I could screw it into the header as a secondary fastening, which also made it quite a bit easier to go about drilling the long holes through the header for the thru-bolt hex heads. Using the auger bit to hog out most of the waste and then a bit of cleaning up around the edges w/ a twist drill pretty much took care of it. My SFIL paid a quick visit in the evening so I had a helper, which of course makes things go much faster and more efficient.

Here it is completed and installed, and the Charger put back in place and hoisted back up. Still gotta do a bit of work to get it hooked up the outlet that is on the ceiling and hang the remote and re-mount the Briggs clock that was previously there, but pretty much done w/ this job. Should be nice for various lifting efforts I'll need in the future.

 

[moparfreak]

Made a bit more progress on the planer, man I thought I could knock this out super quick...life's been getting in the way....anyways, I'm wishing I took good picture of the disassembly, as there's some aspects I'm questionable on, but will just have to use some mechanical common sense as this goes back together. Got the roller gearbox back together, still gotta fiddle with the feed rate switching mechanism a bit as it doesn't seem to operate as smoothly as it should.

And with some difficulty finally got the drive & fan belts on, should have put the drive belt on as I was installing the cutterhead but still managed.

On a different note, when I was installing the hoist and took down that vintage Briggs clock I noticed it had a light in it that had never worked, which I think will be pretty cool. Going to get a new bulb for it, put it back together and re-mount it in a different location off the ceiling.

 

[moparfreak]

One of the things about this planer, is every time I wanted to use it, I'd have to muscle it into place onto a workbench or on the floor or something. It's actually quite heavy, probably 90 lb + or so, and awkward, and I've strained my back moving it before, so I wanted to have a means to use it w/o having to awkwardly position it into place. Decided to clear out one of the bays in the workbench:


Added some drawer slides I had laying around:




With the weight of the planer, I certainly don't trust the slides alone to support, so I fashioned up a little set of swing-out support legs. Used hex bolts & Tee-nuts to serve as a hinge.


Got the planer in place and mounted:




One area where I did have a bit of a goof is the overall height. I didn't account for the height of the support rails & platform, and there's a raised portion, along with the handle that won't fit all the way into the space. Oh well, fortunately it only sticks out a couple inches and I've still gained the functionality I wanted. With the handle being so tall there's really nothing I could do to modify or resolve this, even if I had realized before I started the build, cause the workbench is what it is. Overall I'm happy, and I've got 8+ feet both on the infeed and outfeed sides to I can simply pull it out, set the support feet, hook up power & dust collection and get to planing.


Now back to the Charger!

 

[moparfreak]

Finally got around to building a small rack to hold my various squares and similar items. I enjoy the challenge of these projects of making something useful out of pure scraps.

First found an appropriately sized piece of 3/4" plywood and started making some slots.

Was gonna just put it in the pegboard then but felt it needed a bit more structure, more scraps. Taped the pieces together to cut together on the bandsaw.

Finally put some L-hooks into it and loaded it up on the pegboard. I need to do some organizing and getting the spacing right, but it's nice to have this stuff easy to see and access now. Much improved! Next up I'll repeat somethign similar to fit a few speed squares.

 

[shortykorte]

Nice work on the tool organizing. I like the hutch setup.
Nice install on the hoist. It will come in handy.


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[moparfreak]

Well it has been a long time since last posting on the shop. Beginning of the year always seems to get busy...spent time on some kitchen trim projects (undercab trim, crown, etc) but now ready for some new projects. Worked on a few odds and ends in the shop throughout...

Realized that my Briggs clock I had put up actually had a flourescent bulb in it, so now it lights up, it's kinda like the shop nightlight now.

Did a bit more with the squares and rulers, I've redone this whole pegboard wall so I'll show that in a little while.

Next focusing on making a decent table for the benchtop drill press. It's cramped quarters but I'd like to streamline using this DP, as right now I have issues w/ the handle knocking into the shelf behind it as well as the table that mounts to it (design flaw on my part, I know). So first step is to make up a new handle, I started w/ a scrap of aluminum.

Cross drill for the set screw.

Much easier in a spot w/ tight clearance.

For the table I'm using a leftover table from a Grizzly table that already had some nice hardware in it, T-tracks, etc. It's MDF so not my material of choice, but has a nice laminate covering so it'll do. I also want to have some big slots in there for being able to use quick clamps to hold stuff down, so markup and template rout...

Next up is the fence and fastening method.

 

[shortykorte]

It has been awhile. Clock light will make a great night light. What are you using to hold the Nut-drivers? Nice job on knob. Looks like you’ll need a knurling tool. Lol.


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[moparfreak]

OK, after more long hiatus memorial day weekend gave me some time to work on shop projects again....got a few knocked off my list...

Let's start w/ finishing up the drill press table. For the fence, for quick easy and adjustable, I'm just using a piece of 80/20 since it's got T-slotting on all sides, modular, and also low profile so doesn't interfere with the quill handles like some previous taller fences I had would.

Then, the last thing I need to do is set up a way for it to attach to the DP table. Wanted it to be easy to go on quickly and easy to position repeatably as well, so I ended up with some strips and toggle clamps. I must say it works well. So, I'm gonna call this done.

Certainly not the fanciest approach out there, but I've got now:
- Low profile adjustable fence
- T-tracks for clamping accessories
- Large slots for using quick grip clamps
- Easy to setup and remove
- Reused some parts and hardware I already had, the only thing I bought for this was a 2' piece of 80/20 for a few dollars.

Next I've got a short list of some accessories to build for it as well as some storage for those accessories.

Another piece that's been bugging me for a little while was my old Craftsman combination sander. It's got a 4"x36" belt and a 9" disc. Has a table that I guess from the beginning has always been off of 90degrees in both directions from the belt, which is unfortunate because the 4x36" belt is one of the most common sanders I use for deburring, light material removal, etc.

So, after cleaning up the sander, putting new belt and disc on, making what adjustments I could, I decided to fabricate a quick table for it that would be able to be locked down to a proper 90 degrees.

Real simple, just a piece of 3/4" cabinet grade ply with a nice flat smooth surface to work off of. Then some edges glued on so that it hugs the existing metal table well.

I didn't have to be particularly careful with the edge glueup as I used the table saw to flush & square everything up. Also put a few leveling screws on the underside so I could perfectly dial in the height at all 4 corners and get it nice & square.

Back in place, eventually will tackle this whole sanding table and make it fit and work better for work flow but it gets the job done at the moment.

Feels good to get this done and out of the way. Shop time can be very therapeutic!

 

[moparfreak]

Knocked a few small projects out over the last few weeks, cleared some upper bench storage space:

My oscillating multi tool (OSM) has become more and more handy, and I've collected a few versions and also a number of different attachments. They've been just collecting in a big messy pile for awhile. I had plans in my mind to make a fancy organizer for it but realized I probably had in storage enough various containers and things to make it all work. After sorting through my bins (cuz I never throw anything out - a blessing and a curse), I came up with this. Now it goes down on the shelf below the workbench, easy to see and pull out and setup quickly for a job. Perfect!

Next, right next to that messy pile was all my dremel stuff. Again, very useful tool. I've also had a lot of inherited tools, I have a dremel from my dad as well as grandpa and a whole mess of the little accessories that go along with it. I've also gotten the Lee Valley base and fence for it which has extended the usfeulness of it by quite a bit.

In this case I had in mind a certain way I wanted to organize it, such that all my dremels were hanging and setup ready to grab easily, and the accessories neatly organized as well. So, took some scrap wood and started making a box off a quick sketch:

Then filled it all up and put it into place on a storage shelf above the workbench:

Also took a tip from Woodsmith magazine, I believe it was, and made a quick clamping bar. This makes it easy to constrain a part into place on the table using the T-track slot. It can either be butted up against the part or clamped over the top of it.

Even got to use the new DP table to make it, which made it much easier, just drilled out the slot along the line and then filed it flat.

Had received another one of those nice close-able shelves from my SFIL so I made up a system to mount to the wall. It had already some metal brackets on the back that worked w/ a french cleat type approach so I just adapted to be able to fasten easily to the wall. Made installation quite easy (w/ a second hand in this case).

This one comes in handy as I put all my automotive shop manuals and technical manuals / Haynes / Chiltons stuff in there, closer to the workbench for the cars where I use them. Frees up some more cabinet space for other things.

Finally, I took my Frankenstein standing drill press setup and streamlined it a bit. It used to be this:

Now I took the controller and mounted on the base which just clears up a lot of precious floor space:

All in all it feels good to get a few of these smaller things done. Maybe onto some bigger things next (the Charger perhaps?)...

 

[moparfreak]

Oh and I almost forgot, I can now join the exclusive group of folks w/ a shop dog. Maybe that's why updates have slowed down, but I recently started introducing our new pup to spending time with me in the shop. She's mostly curious about what's going on in here rather than scared which is a good thing....ends up getting sawdust all over her fur.

 

[moparfreak]

Ugh, I got started and the organizing bug hit me...got after my jigsaw stuff...

For blades I hot glued a bunch of PVC scrap offcuts:

Had a couple more of those big yellow Akro bins that stack nicely:

Then did the same w/ my recip saw collection. Blades stack up in the little trays.

Yes this should satisfy my OCD for another week or two:

 

[shortykorte]

Cute shop dog.
Nice, functional and quick projects. Gotta love it. Dremel tool storage is great idea, especially having the tool hanging right there.
Also like the simplicity of the DP table. The large holes, those are for clamps to fit into when needed? On the other DP, what is the box you mounted at base. Looks like you’re using a foot switch for DP. Where’d you get them?


Shorty Korte
Always remember quality in QST

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