Shop Layout Suggestions

[HotShoe]

I've been a long time lurker and have enjoyed seeing all of the awesome garage/shops here. All of your incredible spaces have inspired me to redo my own.

I need some guidance to make the best use of a "do it all" shop. By do it all I mean that my projects entail a variety of steps. I make hand formed aluminum sculptures of cars that include oak bucks. You can see a little sample at HotShoe Studios.

From start to finish I'm grinding/carving oak, using wood tools, shaping/grinding/hammering metal, welding metal, vacuum forming, carving/modeling composite foam, you name it - I'm doing it. Of course all of this creates a mess and organizational nightmare.

Up until now I've just done the best I could by cleaning often and covering things when not in use. Believe me when I say that my dust has dust!

The time has come to actually try and come up with a better plan. Unfortunately I only have a 1,000 square feet of space. 20' x 50' x 17' to be exact. Right now it is just a rectangle blank canvas with a small bathroom in the corner. A twelve foot overhead door is on the opposite end of the bathroom.

Help me plan this space to maximize every inch! Separate process? Dust collection? Should I just cover the machines not in use? What would you do? I need to have an efficient setup and store a variety of metal, wood, supplies. Heck, I have a car on a rotisserie! Most of all, safe and clean. I hate clutter.

I have been searching here like mad and have come across some great ideas. Let's hear some more ideas if possible. How are you guys handling some of these issues?

 

[Jeff_R]

I don't have a lot of suggestions (I am still working on my own workshop)... but I have to say WOW!!!! That is awesome the art that you make. That is a lot of talent and patience that I don't have.

Could you add sliding partition walls between various areas to keep dust down? Something like they have in classrooms or churchs. This would allow you to open it all up when needed, but when you are working on the a particular area keep the dust controlled.

Another idea would be a whole workshop air filter and a central dust collector. You would need to keep the metal separate from the wood though (fire hazard from static electricity).

 

[A_Pmech]

My advice is to put together a dust collection system that will take away the vast majority of the dust you produce. Downdraft tables to do your sanding and grinding on will help significantly.

During the summer, provide substantial ventilation when possible. This will remove dust contaminated air. During the winter or when using air conditioning, use high-volume electrostatic dust filters.

Besides the above, keep any machinery that has open way surfaces or uses lots of oil to lubricate itself covered when not in use. That will go a long way to keeping your machines clean.

Finally, keep your metalworking machines separated from your woodworking machines. Doing so makes it easier to keep the dust and chips from combining. For large projects I install a heavy tarp down the center beam in this photo, isolating the woodworking machines from the metalworking machines:

 

[bobadame]

You have enough room for a mezzanine. Storage up there and above the bathroom. Metal shaping or machine tools under there. Obviously an efficient dust collection system. Do you do any welding on your sculptures? Beautiful work by the way. Folks, you gotta check out his site, truly amazing work there. I'd like to know more about the metalshaping aspect of your work and also mention a couple of sites: www.metalmeet.com and www.allmetalshaping.com

 

[bazzateer]

I was trying to work out the scale then saw the pic with the man (you?). Truly a talent!

 

[HotShoe]

Thanks so much for the great suggestions and compliments! I really appreciate all the help.

I'm not sure how to do multi-quotes here so please forgive me for just answering everything in one broad stroke.

The image is of me standing next to a 1/2 scale piece I did. I typically work in 1/4 scale but I'm doing a full-size piece at the moment so it varies often. It all depends on the client.

I do everything myself including the shaping and gas welding. The pieces are all made out of .050 3003 aluminum and gas welded with a Henrob. 90% of the metal is simply done with the sandbag and mallets, slappers, etc. I also use the english wheel but I often have to planish by hand due to the small, tight curves of the 1/4 scale cars.

Those metal sites are awesome, I'll have to try and spend some time there. I'm pretty much self taught and learning as I go still but I did take a Ron Fournier class that was the best thing I could have ever done. I still by a lot of my supplies from Ron.

I like the partition idea and have been searching for curtain systems. I definitely think a mezzanine is a must to maximize space. Maybe I could keep the wood process isolated that way? I just bought a cheapo HF dust collector and I am researching a system like A_Pmech has (I have shop envy!).

My real problem right now is AC. Summer here will melt your face off. The unit has an existing 2.5 ton compressor but no air handler. I'm rolling the dice and hoping I luck out and it still works. If not, I'll have to figure something out.

It's going to be an interesting challenge. The dust problem is my number one priority. I have to keep my space looking like an F1 shop to please my clients. I've found that my bracket of customers truly believes a shop space reflects the quality of work so I better meet their expectations if I want to feed my kids!

DOH!!! Just saw the multi quote, what a knucklehead! Sorry.

 

[35mm]

Wow, that is some impressive art that I assume I can not afford (but sure want).

 

[HotShoe]

Well, I finally signed the deal and got the keys. Looks like I've got a lot of work to do.

My first major challenge is what to do with the existing floor. There currently is old VCT down that is coming up very easy but I have to decide what to do with the remaining residue/cement. Searched here and found a lot of great ideas about how to tackle this. Hopefully I'll find one that works!

 

[Zeke]

I'd separate the welding and grinding from the rest of the shop. Dust control is a comfort as well as a safety issue, spend some time and money on this facet. You may want to consider a clean room as well for assembly and storage of work in progress. You could make this area your gallery as well. This 3rd area might also be a good place for your vac form machine.

Sizing of each area is determined by how you use your space and tools.