The R&D Department

[andyaus]

 

[snapsimo]

Fantastic. It's coming along nicely.


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[kensbey]

Few more bits and pieces done:

Got the window framed finally. Used a larger size aluminium angle for this. <$20 worth and I think it's come up really good. Hard to get a good photo when it's bright outside.
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I also started work on the next benchtop. One of the sleepers had a saw cut in the underside, and I needed the length, so the first job was to patch that up. I found some appropriately thick board and glued it in place with as much wood glue as possible.

Once dry, cut and sanded flush. This will be on the underside, so i'm just concerned with strength, not aesthetics.
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Cut everything to length, drilled for dowels and routed spots for joiners. This top is a little trickier because one of the lengths has to come from several smaller pieces.
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Clamped and glued. The massive pipe clampes are a lend from a friend. They are absolutely fantastic, and really make the whole job a LOT easier.
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Hopefully I can start finishing the top side this weekend.

 

[1/2 Cup]

kensbey I like what you have done with your window trims, they look nice and sharp.

The bench top is progressing well too..

Regards

 

[RobSmith]

Storing tyres in the sun is not good... find another dark place for them. After talking to many tyre manufacturers I have been told to store them mounted, inflated and out of the the sun... any light actually. nice shed though !

 

[kensbey]

Thanks cup!

Storing tyres in the sun is not good... find another dark place for them. After talking to many tyre manufacturers I have been told to store them mounted, inflated and out of the the sun... any light actually. nice shed though !

I was wondering about this. Most people store them upright on a rack, but I feel like this would deform the rubber over time. 4 of them in that stack are stuffed anyway, just keeping for rims. I will find another spot I guess.

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[bj383ss]

Love your shed. Your attention to detail is very refreshing. Your electronics bench came out a treat. Look forward to your drawer build. I have been wanting a CNC. I built a 3D router that does manual but those labels you made are just another reason for me to build a CNC now.

Bret

 

[kensbey]

Love your shed. Your attention to detail is very refreshing. Your electronics bench came out a treat. Look forward to your drawer build. I have been wanting a CNC. I built a 3D router that does manual but those labels you made are just another reason for me to build a CNC now.

Bret

Thanks for the kind words Bret! The CNC is definitely useful for a lot of jobs! I need to hurry up and get everything sorted so I can move the big one in.

 

[kensbey]

Got the first lot of melamine drawers built and installed in the electronics bench over the weekend.Was a lot of mucking around with sizes for these, the lower 2 should come together much faster.

They will need fronts at some point, but the priority is getting them all built to get all the parts organised.

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[snapsimo]

I love stuff!! [emoji38][emoji38][emoji38]


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[1/2 Cup]

kensbey, absolutely fantastic work.

Regards

 

[Grumblebum]

Your bench is coming along nicely kensbey. I hear you on the fiddly drawer assembly.

Also good idea with the trim on the window, much cleaner look.

How did you go with the rain up there lately ?

GB

 

[kensbey]

Your bench is coming along nicely kensbey. I hear you on the fiddly drawer assembly.

Also good idea with the trim on the window, much cleaner look.

How did you go with the rain up there lately ?

GB

Thanks GB! We were relatively unscathed by the rain/flooding. Our block is kind of up a hill, so there isn't a huge risk for us.

Was some super heavy rain though, so I'm happy to report the shed is completely water tight! [emoji2]

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[kensbey]

Got some time today to get the PC bench finished and in place..

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Still needs the shelf for the tower and a sliding keyboard tray, but at least it's in position and no longer taking up my car work space.

Sound gear installed:
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Rear Speakers Up:

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[1/2 Cup]

kensbey, progressing well.

Neat and clean lines, love it..

 

[kensbey]

Something big and red is coming....

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[kensbey]

Ta da!

So this Happened:
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When I originally built the shed, I always has a two post lift in the back of my mind. I made the slab a little stronger etc with provision for this. After starting to work in the space, however, I started to dislike the idea of the inside post in the middle of the shed. If the shed was another 2 meters wider (standard 3 bay) then it wouldn't be an issue. With a two post, it would be very difficult to get a second car into the shed if needed.

A few months ago a friend of mine purchased a similar scissor type hoist. After seeing and using it, I quickly decided that it was a much better solution for my space. The lift height is the same, you still have access to everything important, and the footprint when it's not in use is the same size as the car. Its under 200mm high when its down, so it's easy enough to work over the top of, and you can even leave it at waist height as a work surface! You can't park a car underneath like a two post, but it leaves plenty of space to get another car in beside it, which I wouldn't be able to with a two post.

The only issue is that they are a lot more expensive than a two post. Which put a new one out of my budget. Thus I have been scouring the internet for a good condition 2nd hand model for quite a while. One finally popped up, and off we went.

Unfortunately, I don't have photos of us installing it, which turned out to be an all day job. The quick version is that we borrowed a bunch of engine cranes and juggled them around from end to end.

Power unit tucks in neatly under the storage shelves.
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Needless to say, I am very happy at the moment.
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[Grumblebum]

That looks awesome kensbey.

GB

 

[1/2 Cup]

kensbey. nice one, now I am envious..

 

[kensbey]

Here's another little shed project that I was able to get almost completed on the weekend: A ceiling/storage area over the top of the electronics benches. This is predominately for storing large lengths of material when not being used, but is also going to house a row of LED downlights over the benches.

Some of these photos were taken before the hoist went in btw.

The basic structure is made up of 100x50x1.5 C purlins.
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chop chop chop
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Squaring up the side supports:
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String line to get brackets positioned with centre post:
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Basic structure up:
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Top hats and sheets in:
View media item 71858Just one more small sheet needed for the middle. I'll take some more photos once the lights are in and I've cleaned up a bit.

This also created enough space to finally move the mill out of storage and into the shed.
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[octane_matty]

I don't have the words to describe the lift jealous I have right now Kensbey [emoji22]

How does the little Hafco mill go? Smooth cuts? Tempted to buy one for small jobs but would really love a solid vintage piece in the long term if funds permit.

 

[kensbey]

I don't have the words to describe the lift jealous I have right now Kensbey [emoji22]

How does the little Hafco mill go? Smooth cuts? Tempted to buy one for small jobs but would really love a solid vintage piece in the long term if funds permit.

Thanks Matty,
I am regularly going into the shed just to look at the lift. The e36 has gone up and down several times already...it is going to end up super clean underneath I think. hahaha.

I love the HM46. It's the biggest benchtop mill I could find in Aus. So far I have machined mostly aluminium, which it just loves. I have been pretty surprised by what it is capable of. Next week I am modifying some porsche calipers to fit on a mates Z4. That should be fun

Obviously the larger and more rigid the machine the better, but you have to draw the line somewhere. I am part way through making all the bits to CNC the HM46, and that would have been a lot more expensive process with a larger knee mill. Go as big as you can afford

 

[kensbey]

Got some interesting stuff done in the R&D department today.

I set up a temporary enclosure for the mill using predominately electrical conduit and a plastic tarp. Not bad for $30 lol. This will be replaced with a more permanent enclosure once the CNC conversion is complete, but I just needed something quick so it was usable.
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A buddy has a Z4 that we did a brake upgrade on today. The upgrade uses porsche boxter S calipers on E46 M3 rotors.
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To get the calipers to fit, you have to machine some material off the mounting points. In the photo below, the left side is done, the right is not yet:
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done:
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looking good on the car. He is going to paint them before final fitting.
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[1/2 Cup]

Kensby, nice work on the calipers..

 

[BoilermakerFan]

Ah man, I just discovered this thread but you were burned by PB too. Planning to rehost the pics?

 

[kensbey]

Ah man, I just discovered this thread but you were burned by PB too. Planning to rehost the pics?

Yeah ***** hey. When PB started this whole debacle I backed up most of my threads. Unfortunately I did it on a lunch break so all the backups are at work. I'll do some fixing on monday.

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[kensbey]

Photobucket Can **** It.

Ok so I finally got the chance to got through and fix all the photo links that broke when Photobucket screwed everybody. I guess this is a lesson in cloud storage... nothing is forever.

For anyone who is wondering, here is a method to back up a whole thread:

• Find the thread in Garage Gallery (or equiv) or via your "started threads" in your profile.
• Instead of clicking on the title (which would navigate to the last page of the thread), click the small 'view all' link at the end of the line
• This will show the whole thread on one page. Make sure you wait for all the pictures on the page to load, might take a while for large threads.
• Right click on the page and press 'Save as...'. Navigate to a folder on your computer and save the page.
• This will create two things in the selected folder: A .html file of the page, and a folder called '[page name]_files'. The folder contains all the pictures and resources on the page, so the html file is completely readable offline.

Most of you probably already know this, but I figured it might help someone.

BACK TO THE SHED!

I got the mezzanine/storage finished, and the down lights in over the bench.

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There is a few joins in the ceiling that need tidying up, but for the most part it's complete. There is sooo much light over the benches now, and massive amounts of space on top for material and low use items. Mission accomplished.

I serviced the E36 on the weekend, here was my low cost solution for an oil drain for the hoist:
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The drum was waste from work and the funnel was a few dollars from SCA. Not bad for almost zero cost, and it is super easy to hide away when not in use.

 

[lidz]

Great work! Is it possible to get a few more photos of the mezzanine from a bit further back? Would love to do something similar in my shed.

cheers, Tim

 

[kensbey]

Great work! Is it possible to get a few more photos of the mezzanine from a bit further back? Would love to do something similar in my shed.

cheers, Tim

Thanks Tim!

I do intend to post some photos showing the current state of the whole space shortly. I didn't yet because everything is a massive mess while I get stuff sorted away properly. There are some photos of the basic structure a few posts back.

Because it's all hanging off the shed frame, my mezzanine is not going to be rated for huge amounts of weight. This is not an issue for me, as i'm only storing spare timber, exhaust parts etc. If you want something load rated for serious storage you would need to have the shed engineered for it or go for a design where the mezzanine has it's own posts.

I'll try to get some more photos for you shortly.

 

[kensbey]

Great work! Is it possible to get a few more photos of the mezzanine from a bit further back? Would love to do something similar in my shed.

cheers, Tim

Here you go Tim, i found a photo on my phone that i didn't post that shows some more detail of the basic frame. I think one end wasn't fixed at this point so it's not quite straight yet , but you get the idea.

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[1/2 Cup]

Kensbey, top job all round..

Regards

 

[JAKE-THE-TOOL-MAN]

Very functional neat garage! I also love Brisbane, great area!

 

[lidz]

That's a great photo, thanks Kensbey! Similar to yourself I'm not planning to store anything huge up there, just small car parts, tubs of kids toys, chrissy decorations, etc & want to avoid posts that cut into my floor space

 

[kensbey]

That's a great photo, thanks Kensbey! Similar to yourself I'm not planning to store anything huge up there, just small car parts, tubs of kids toys, chrissy decorations, etc & want to avoid posts that cut into my floor space

The only really tricky part of putting it up was that the centre portal frame in my shed is larger than the two side ones. this means the centre post is deeper and sticks out more from the wall more. So I had to rig up brackets on the side posts to get the rear beam parallel to the wall. That's what the string line was for in the earlier photos. Getting that all lined up took a fair amount of tweaking.

Other than that the rest was pretty straight forward. You can see how I pre-assembled the side pieces square, then raised them up and pinned them level.

I used 100x50x1.5 C purlins, which are probably a little over-engineered, but i got them cheap, and they are the same size as the side portal frames, which makes the whole think look like it was meant to be there.

Let me know if you want to know anything else.

 

[cros13]

Just read through your whole build man. I like it!

I quite like the mezzanine level you made. Im probably going to try making something similar too. Where did you get all your insulation and the sheeting for your walls? i Want to do something like that too in my garage.

I like the hoist, but for me, im still going to try and get a 2 post, and have to deal with one with a baseplate.

Rudi.

 

[kensbey]

Just read through your whole build man. I like it!

I quite like the mezzanine level you made. Im probably going to try making something similar too. Where did you get all your insulation and the sheeting for your walls? i Want to do something like that too in my garage.

I like the hoist, but for me, im still going to try and get a 2 post, and have to deal with one with a baseplate.

Rudi.

Thanks

Insulation and Sheeting is from bunnings. Insulation is just standard wall insulation, I can't remember what thickness, but it was almost perfectly the thickness between the walls and Sheeting.
The sheeting itself is 16mm HMR melamine. It's designed for building kitchen cabinets I believe. I wanted something that was thick enough to hang stuff on directly, and that I didn't have to paint or finish.

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[Achtung73]

Just read through your whole build man. I like it!

I quite like the mezzanine level you made. Im probably going to try making something similar too. Where did you get all your insulation and the sheeting for your walls? i Want to do something like that too in my garage.

I like the hoist, but for me, im still going to try and get a 2 post, and have to deal with one with a baseplate.

Rudi.

I like it too and from what I can see it looks to be strong enough but these storage solutions whilst being efficient use of space can be concerning.

Remember:
Things on overhead storage can by their very definition fall on your head
A lot of light stuff adds to being a heavy load
Store heavier stuff near the supports.
Look for the weak links in your structure: How is the load being transferred to the floor? Are the fasteners strong enough? Does it require maintenance?
Over-engineering can be surprisingly cost effective, going up from a 2" x 4" to a 2" x 6" is relatively cheap, particularly if you choose where to upgrade intelligently.

This is a nice looking set-up though.

 

[kensbey]

I like it too and from what I can see it looks to be strong enough but these storage solutions whilst being efficient use of space can be concerning.

Remember:
Things on overhead storage can by their very definition fall on your head
A lot of light stuff adds to being a heavy load
Store heavier stuff near the supports.
Look for the weak links in your structure: How is the load being transferred to the floor? Are the fasteners strong enough? Does it require maintenance?
Over-engineering can be surprisingly cost effective, going up from a 2" x 4" to a 2" x 6" is relatively cheap, particularly if you choose where to upgrade intelligently.

This is a nice looking set-up though.

Well said. All good points. There is plenty of info online regarding the load rating of the steel sections. Likewise most reputable fastener manufacturers post the ratings of their parts.

Most importantly, if you're not 100% sure with what you are doing, find someone to help or consult a professional. Safety first.

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[BoilermakerFan]

Glad to see you got the pics back in the thread! Now I'll have to go back and read it from the beginning!

 

[kensbey]

Glad to see you got the pics back in the thread! Now I'll have to go back and read it from the beginning!

Enjoy!

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