The Fallible Garage

[FallibleFlyer]

Overview
Long time lurker, rarely a poster here. My wife and I just moved all the way from New York to Arizona, with this comes a new house with a new garage and a great opportunity to learn from the shortcomings of my last setup and build what I want. It certainly won't be the most fascinating or elaborate garage thread, but it will be some motivation for me to continue. So, follow along and give me any advice and comments you desire on a relatively average garage/shop

The New Garage

The new garage is a three car garage with the third bay being a tandem bay. The area I'm designating as the 'shop area' is 14'x21' and has to run triple duty as primary storage, shop, and parking spot for my 74' CJ5. The general philosophy/approach I'm taking is that all working surfaces and tools should be mobile. Because my work area has to share with a vehicle, it makes sense to me that I should be able to move everything around when and where needed. Lighting is limited with only two overhead bulbs, though this is an easy fix. Power is located on only one wall, so I will have to figure out how to get around that problem (run power or use longer cords). I am not a professional woodworker, metalworker, welder, mechanic, etc. but I do enjoy the lot and the shop will eventually have to accommodate all of the above. Overall, I'm going to try and embrace the whole "Mise en place", everything has its place. I'm tired of always scavenging for the tool I need...

Latest Photo
For those that don't wish to hunt and peck or new comers, I'll try to keep the latest overall progress photo here.
View media item 103464

 

[FallibleFlyer]

The Sander Table
Nothing special, its a Harbor Freight 12" Disc sander.

Absolutely tired of working with it on the floor or having to heft it up onto my welding table (too high), so its time to build a small table for it. If nothing else, its good practice and will get me back into some home fab.

• Oversized to accomodate a small amount of "counter space" for in progress work
• Shelf underneath for whatever makes sense, or storing the sander itself
• Wheels, has to be mobile
• Made of 2" 16ga square tubing, bought it as drops
• End height should be around 30", once the grinder is ontop its work height will be closer to 38, maybe a hair lower.

Cut and angled some steel, will start welding it up Friday or Saturday evening.

 

[FallibleFlyer]

The Sander Table (part 2)
Well, I completely forgot about the holidays and family etc. during my last post. As such I didn't get a chance to run out to the garage to make some progress, but today I forced myself out there. After all, I only have a few weeks left till my beloved CJ5 makes its way to its new home.

So, over the last few days I got the entire frame welded up and assembled. All that's left to do is to cut and weld on the expanded steel shelf, clean up the welds, and paint it. Overall I'm quite happy with how this first small project here is going. The height turned out perfect for my preference and the extra side space will be perfect for stacking in progress stock. As for paint, I haven't decided whether or not to paint the top. If I paint it, it will look nice... for a while. I'm tempted to leave it bare and just keep it oiled much like my iron welding table. Thoughts?

(something warped a little on one of the legs, so I had to fill a decent gap on one leg...

 

[turbowoodworker]

Nice job on the table.
Where in AZ are you located?
Subscribed too.

 

[FallibleFlyer]

Thanks! We moved to the West side of Phoenix, quite nice so far (though is not Summer yet.)

 

[turbowoodworker]

Welcome to PHX. I lived in Ahwatukee for 20 years. Now in NC. I miss that nice dry heat.

 

[rattle_snake]

Welcome to AZ.
Having everything on wheels is a great plan.
I'd paint the sander table. Oil will collect dust. Pick a color and use it on the other items in your list.

 

[Terranova]

Table looks great?
What casters did you use?
Will they hold up to the weight of the table plus sander? I built a welder cart and grossly under estimated on the weight of the table and therefore the type/strength of casters.

Subscribed as I am also in a three car with a third bay shop.
T

 

[FallibleFlyer]

Welcome to AZ.
Having everything on wheels is a great plan.
I'd paint the sander table. Oil will collect dust. Pick a color and use it on the other items in your list.

Yeah, my concern with paint is how easily it will get scratched from the staging of rough metal on it. Any recommendation on paint that might hold up well? I was planning to paint the legs regardless as they're lower "traffic".

Table looks great?
What casters did you use?
Will they hold up to the weight of the table plus sander? I built a welder cart and grossly under estimated on the weight of the table and therefore the type/strength of casters.

Subscribed as I am also in a three car with a third bay shop.
T

Thanks for the sub!

They're 90lb locking 2" castors, same ones I used on my welding table that have held up well. Though after some thought I'm considering changing them out to larger wheels that can clear the expansion cracks in the floor.

Some other considerations last night are to add hangers for my angle grinders and mount for a vice, would let it serve as a generic grinding station. On the fence on whether or not to include a hook for my faceshield

 

[FallibleFlyer]

Side Track Scavenge
No progress on the sander table, but I spent some time salvaging some steel from an old kiln with my father. Also saved my Grandfather's old vice

Six pieces of steel, roughly 10 gauge 3'x2'
Boxed pieces thats 2x2' and 1/4", maybe 3/16"

Vice is a No. 40? Howard Iron. Limited research suggests its 100+ years old.

Hopefully get back to the table in the next couple days, then move onto the next.

 

[sean Buick 76]

Looking really good thanks for sharing! It is a challenge but you can do it! I find documenting my projects helps keep up my momentum...

 

[FallibleFlyer]

Table 'Complete'
Well, today I got out there for just long enough to weld on the expanded shield shelf and low an behold my measuring doesn't **** because the sander fits down there for storage! Was quite a happy moment for me. Also hit all the welds with the braided wire cup just to get it cleaned up for now.

I didn't paint the thing yet, though I think I will. I haven't yet because I've ran into a few things I want to modify and I suspect there will be more. Going to remove the castors and replace them with two static legs and a pair of non-swiveling castors. It won't be as mobile, but currently its too wiggly for the work. Live and learn This will also necessitate adding a handle (which I suspect could be combined with storage for my angle grinders.

Then I thought about adding a space for a vice on this little guy...

Vice Resto 1 (Getting Side Tracked)
Once again I was side tracked by something not on my list. My grandfather's vice was sitting in the corner of the garage with fifty plus years of mouse poop and general grime on it. Figured I'd at least start by cleaning it up, so I hit it with the power washer (did nothing) and finally the wire cup wheel.

Close up of old weld/repair

Sure enough a No. 40 Howard Iron

A few trailing questions...

1. Its still quite dirty and I'm out of tools to clean it with. What are my options? I've found a local shop that appears to do auto part cleaning, was considering reachout out to them.
2. What I thought was another pile of ****, turned out to be a gigantic booger weld repair that my grandfather must have done many years ago. Should I be nervous?
3. Anyone happen to have one of these and know if the stud coming out the bottom is removable? I don't really have a 6" thick bench to mount this on...
4. The jaws are pinned on with old nails, typical?

 

[FallibleFlyer]

New Toys and some Cleanup
Been a while since an update, but hasn't been much update. I purchased a load of steel to build new work tables and a picnic table request by SHMBO. Didn't make much progress on it before it dawned on me that I only had a week or so until the jeep arrived and my tools were still in boxes. So, I went out and bought myself a big shiny toolbox.

Also got myself a new welder, I know its only the new HF Vulcan, but after some extensive internet searching, I couldn't find and real negative reviews. lots of speculation and worries about lack of support and parts. However, when I was at the store I saw every major consumable i thought I might need. So, with the one year guarantee, I said lets give it a go. So far, I dig it.

Plenty of space for the jeep!

 

[Bib Overalls]

I'd grind the ****** on the vice off. If the repair holds it means the weld got good penetration (which I doubt). If it does fail it can be rewelded with a bit of grinding, a preheat, and the correct rod.

 

[FallibleFlyer]

I'd grind the ****** on the vice off. If the repair holds it means the weld got good penetration (which I doubt). If it does fail it can be rewelded with a bit of grinding, a preheat, and the correct rod.

Thanks, I appreciate the tip, I've never tried to weld anything cast and I'm sure if I ever do try to repair the vice I'll be seeking as much advice as possible. I haven't really decided what I'm going to use this one for yet. Since it has an exposed gear I don't really want to use it for grinding, I may wind up drilling a hole in the new welding table I'm building and mounting it there.

Speaking of welding table.. I'm at a crossroads. My old top is made up of two cast iron table saw tops. I've use these for a few years now and they've served me well. The heavy, hard, and relatively flat. Biggest issue I've had has been with clamping stuff down.. The holes in the middle provide some fantastic access to pieces in the middle of the table, but the cast bottom has ribs in it for reinforcement that make the seat for the clamps sit at angles and sometimes slip. I've been considering replacing the top with three pieces of 12x27x.5" flat stock with one inch gaps between. This would give me a table just over 2x3' with some nice gaps for clamping. Other option is to retrofit a flat bottom under my cast iron top, just not sure its worth keeping them.

 

[FallibleFlyer]

Jeep Arrived
Welp the jeep is here safe and sound, and it even fits in its home! Sadly, it doesn't run yet and leaks like a sieve (hence the giant cardboard litter box underneath.) Clearance is a bit tight with the shelves, but I rarely access that stuff, so I think it'll be fine.

With the jeep back in its place I was able to get a few hours back into the new welding table and get the main frames cut, sanded, and welded. The new sander table was at the perfect height and made the work comfortable. I cannot say the same for the saw, as you may notice its on the floor of the garage. For now, my plan is to reuse the old table saw tops on the welding table and just bolt them on. Eventually I will cut it all off and weld on a flat stock top.

They're not the cleanest welds, but 10x better than my old flux core welder could ever do; so overall I'm happy.

With the jeep in place the space is a bit tight, but I was able to do the work and roll it all out of the way without a whole lot of effort. The plan is the welding table will include a pull out for the bandsaw so it no longer is used on the floor. I struggled to justify using more floor space just for another cart for it since its used so infrequently, this seemed a good solution (we'll see how it plays out..)

 

[mineallmine]

Looks Great! Nice use of the space. I can't wait to finish organizing my shop and get out there working again. I enjoy fabricating stuff and can't wait to get back at it. Built my own welding table as well and really enjoyed it. Keep the pics coming

 

[marty_p]

I like what you've done with the place!

And btw, Jeep wave!

 

[FallibleFlyer]

I like what you've done with the place!

And btw, Jeep wave!

Thank you very much, quite the collection according to your signature!

 

[BoilermakerFan]

Is there any reason why you can't park your vehicle in the driveway and move the Jeep up to it's former spot? Even if it's just for a short term until summer time so you have room to work and get the other stuff done/put away?

 

[FallibleFlyer]

Is there any reason why you can't park your vehicle in the driveway and move the Jeep up to it's former spot? Even if it's just for a short term until summer time so you have room to work and get the other stuff done/put away?

I certainly can and will back out the Cherokee for projects demanding more space. However, I don't generally like leaving my vehicle parked in the driveway. At our last house, the truck I owned prior to the Cherokee was broken into several times because it had to sit in the driveway. This house feels like it's in a better neighborhood, but the driveway is only a car length long and the casual opportunistic thief wouldn't have to even leave the sidewalk... So, no, other than my fears

 

[FallibleFlyer]

Welding Table Frame Progress
Got out in the garage this morning for around four hours and made some really good progress. Got the rest of the frame pieces cut, sanded, and welded up. This is easily the largest project I've taken on, and as such there were some lessons learned along the way.

I had a fair amount of trouble with pieces that were perfectly perpendicular warping out of as they cooled. Ended up doing a fair amount of cutting and rewelding, but I think I am attributing that to trying to tack four corners for every upright. The second tier I did by only tacking the "non pointed" sides of contact between the risers and frame. While they still warped a little it give me some wiggle room so I could lay the new frame on top and pull everything square.

Once that was complete, I pulled it off of the table to fully weld. First time I've also welded over my head and as a result I singed a few hairs... oh well. I still need to finish welding the interior joints on the risers. May or may not do that later tonight. Below is a shot of my welds, I'm still learning but I don't think they look awful. To me, they look a bit tall, but I wasn't able to get the right setting or speed dialed in to reduce it. Thoughts?

I also clamped in the angle iron to mock up how I want the saw to sit. The idea being I will make a new frame for the saw to sit on and it will ride in the angle iron. The plan would be to add some pins on the rear to create a stop point so it can't be pulled out to far, a handle, and some swing down legs to support the cantilevered side. I'm not too concerned about the strength of the setup, but I am a bit nervous about vibrations and reverberations from the saw being on a moveable system. I may see about getting a rubber seat for it to sit on.

 

[BukitCase]

Hard to tell from the pics; can your saw be pulled out far enough to allow it to go full vertical? If not I don't think you're gonna like it, I know I wouldn't. If so, it'd be great for the small space... Steve

 

[Djui5]

Nice CJ

 

[BoilermakerFan]

I certainly can and will back out the Cherokee for projects demanding more space. However, I don't generally like leaving my vehicle parked in the driveway. At our last house, the truck I owned prior to the Cherokee was broken into several times because it had to sit in the driveway. This house feels like it's in a better neighborhood, but the driveway is only a car length long and the casual opportunistic thief wouldn't have to even leave the sidewalk... So, no, other than my fears

Bummer that break ins are that big of a problem. I live in the city here, but usually the only car break ins are kids or young men grabbing cash from unlocked cars. So our cars are parked in the driveway all the time. My garage is just a big yard barn.

 

[Unruh]

Looks like you are putting your stamp on that space! How do you like that toolbox. The drawer layout is pretty sweet!

 

[FallibleFlyer]

Hard to tell from the pics; can your saw be pulled out far enough to allow it to go full vertical? If not I don't think you're gonna like it, I know I wouldn't. If so, it'd be great for the small space... Steve

Yup, the plan is it will be able to pull the full length of the saw out to enable its full range of motion. There is somehting like 6-8" extra horizontal space which should enable the drawer/pull-out to fully expose the saw.

Looks like you are putting your stamp on that space! How do you like that toolbox. The drawer layout is pretty sweet!

Thanks, I appreciate the feedback. Overall I really like the toolbox. Picked it up for just under $500 shipped to my door. It holds all my tools and drawers feel solid. My only complaint is that it wobbles a bit, its really just due to my concrete not being perfectly flat... but its annoying.



No pictures from yesterday, but I was able to get some wheels tacked onto the base. Ended up doing the same approach most do with welding on some plates for the casters to bolt to. Hold pretty solid when the wheels are locked and glides nicely when they're not. The steel I used for the caster mounts was cut from one of the walls of that old kiln I recycled. I noticed when I was grinding the edges straight that it was throwing off some seriously long, bright and seemingly "long burning" sparks. I'm not sure what that means about this steel, but thought it was interesting.

Getting the casters on was an important step for me as it will allow me to plan out and get the pull out for the saw finished. Needed the final height to build the legs for the saw to sit on when its out.

 

[FallibleFlyer]

Welding Table Continued
Minor update for today. As I previously mentioned I was able to get the casters mounted today. I still need to finish welding them on, but there is plenty of that elsewhere as well. The castors work well and the thing glides on ice when they're unlocked and sits like a rock when they are.

Made some good progress on the pull out for the saw. Got the main frame cut out and welded up. Once that was done I tacked on the tracks to get a feeling for how its all going to sit. The frame needs to be open on the underside to allow access to the nut backing the fence to adjust for miters.

Also made a decision on the top. Three pieces of 0.5x12x27" on 1.5" gaps to fit my bar clamps nicely. Will do the 'standard' bolts welded underneath to assist with leveling, haven't decided on four or six bolts per piece. Also considering putting the top's mounting points on slots so it can be slid together into one solid top. Thoughts?

 

[FallibleFlyer]

The Little Things
Had a little bit of time between getting home and the normal evening rituals so I decided to pop out to the garage and make a bit of progress. I started by grinding down the drawer's welds. I haven't decided if I want to actually clean up all the welds on the entire table, but these would be in the way of function. When that was completed I decided that the drawer needed a handle and I didn't want to buy one.

Its quite simple and not that pretty; made of some 1/2" square tubing. I miter cut, sanded, and welded it all up. I suppose I could have bought a nicer one from a big box store and just screwed it on. On the other hand, this only cost me $0.10 and every time I grab it it might be a whee bit more satisfactory, because I made it. Anyone else share this feeling?

Plan is to finish up the table's fabrication on Saturday come hell or high water so stay tuned! Are these minor updates worth while? Or is the general preference for "hey I made a thing" type posts.

 

[drivesitfar]

FF: you might not get a lot of the members doing a RA RA HIP HIP HOORAY when you document small improvements after each day, but for the members that are learning and want to see how it is done step by step I guarantee you they will give you KUDOS LATER.

so if you have time to take plenty of picture and give your thoughts about each step it will be a valuable tool for some that is for certain.

good luck and I just noticed you had a thread so i'll go back and read when i have more time.

cheers

 

[FallibleFlyer]

FF: you might not get a lot of the members doing a RA RA HIP HIP HOORAY when you document small improvements after each day, but for the members that are learning and want to see how it is done step by step I guarantee you they will give you KUDOS LATER.

so if you have time to take plenty of picture and give your thoughts about each step it will be a valuable tool for some that is for certain.

good luck and I just noticed you had a thread so i'll go back and read when i have more time.

cheers

Perhaps my daily updates can at least prove to someone else they're not the slowest

 

[jp828108]

Not sure how other members feel, but I enjoy updates even if they are small. I get that working, friends, family, and life gets in the way of making huge progress. So to me it is nice to see even small updates, and see things progress in more of a real time speed.

 

[drivesitfar]

FF: TOO FUNNY!

yep some of the members have started a thread after the fact taking you from the beginning where they steadily do what looks like a week's work in a couple days. so their 18 month long project took 3 months on the thread or something like that.

anyway yes steady as she goes is great whether you did a good days work or you only got 10 minutes or a couple hours to work on a project cause we all have stuff going on even if it's just to walk the dog or take the kids or grand kids to a movie.

your welds looked pretty good, but i'm not a welder. are you happy with them and I haven't read your thread yet to see how much welding you've done and I will later.

cheers

 

[FallibleFlyer]

Welding Table - The Saw
Well, I got the pull out for the saw 90% complete. Still need to add in some small risers for the saw to let it clear some stuff as well as round over some sharp edges and welds.

As you can see in the photos, there are stops for the slide to keep it from coming out and from going in to far. Also added a little wrap over to prevent any potential tippage. There is also a single leg that folds out from within the frame. I was orginally planning to add a spring to try and make it "snap" open and closed, might still. We'll see.

 

[StormcrowAz]

Hello from a fellow Phoenix west-side resident! Definitely appreciate the old Jeeps. Looks like you are doing some clean work there. The welding table is shaping up nicely and the saw-slide is very creative. I recently purchased the cheap version of that 4x6 and just finished up the cart for it. Also, you can count me in on the “feels good because I made it” group. While there are occasions where it makes sense to simply purchase something, it is enjoyable/cathartic to make things. As the saying goes – “Life is journey, not a destination”.

Thanks for posting and look forward to more updates.

 

[FallibleFlyer]

Hello from a fellow Phoenix west-side resident! Definitely appreciate the old Jeeps. Looks like you are doing some clean work there. The welding table is shaping up nicely and the saw-slide is very creative. I recently purchased the cheap version of that 4x6 and just finished up the cart for it. Also, you can count me in on the “feels good because I made it” group. While there are occasions where it makes sense to simply purchase something, it is enjoyable/cathartic to make things. As the saying goes – “Life is journey, not a destination”.

Thanks for posting and look forward to more updates.

Right on! That Hummer in the avatar yours?

 

[rattle_snake]

Nice work on the slide out. Good to see someone who can think and create cool stuff, whereas the majority of the population on earth can not.

For my bandsaw, I'm waiting for stormcrow to finish pimping his cart out, then he will buy a higher end band saw, and I'll get his. :

 

[FallibleFlyer]

Welding Table (nearly) done
I know... "come hell or high water". Well, I didn't quite finish; but its darn close! I'm not sure how the heck people get these projects done so fast, it truly is impressive. However, today I got the top mounted and some of the shelves welded in.

It took much longer to do all of the drilling and welding of the bolts for the top than I really expected. For those thinking of doing it yourself, its worth noting, you likely don't need to waste your money on grade 8 bolts as the welding process ruins the temper anyhow ... I ended up drilling the holes, dropping the plates ontop of the bolt in the holes. Then tacked the bolts to the plates, pulled it all off and finished welding.

I didn't have a long enough extension for my welder to run at 220v, so the penetration wasn't really what I had hoped for. However, it held fast during the leveling of the plates.

I wound up using some 1.5" square tubing for spacers between the plates, worked well.

Here is a couple shots of where it sits now. I still need to finish off the one side of the lower shelf along with the riser for the saw and varying hooks etc. for clamps. The right side of the lower shelf I'm planning to be solid so I can put my vises and other heavy objects down there.

I'm absolutely staggered at how much even 1/2" plate can flex, fortunately the bolts did a fantastic job at bringing it all in.

 

[StormcrowAz]

Looks like your table is coming along nicely. I’m definitely not one of those “gets projects done quickly” people. Maybe if I won the lottery and had more time to spend in the shop…

Right on! That Hummer in the avatar yours?

Yes, sir. 1997 HMC4. I think I’m just about ready to give her a bath and put it up for sale.

For my bandsaw, I'm waiting for stormcrow to finish pimping his cart out, then he will buy a higher end band saw, and I'll get his. :

Bwahahahaha! If I win that lottery it’s all yours.

 

[drivesitfar]

FF: interesting idea with the leveling bolts. i'll have to watch and maybe learn how that works for you cause i hadn't thought of that.

you asked about my REED 106 (big vise) on it's pipe stand that is welded to a round piece of plate. i put up some information in my thread, but thought you might like the link without doing a search for VISE & GRINDER STANDS so here it is:

https://www.garagejournal.com/forum/showthread.php?t=252799

also i mentioned that my stand isn't very sturdy so bolting it down might be my option unless i weld some more plate to the top or bottom of it's base. the stand a guy built for my big Parker 956 was one that worked very well on it's own, but it was a bit harder to move around cause I bet the stand weighed close to 250 and the vise maybe another 130 pounds.

also just an FYI some of the members have ELVES (friends, kids, clients or help) getting things done so quickly and others are retired and we have 6 SATURDAYS & a SUNDAY every week.

cheers