Zengineer's Metal Work Shoppe

[Zengineer]

Ye olde metal work shoppe. (Zengineer's Wood Work Shoppe can be found at this link here)

You can see my previous shop here: https://www.garagejournal.com/forum/showthread.php?t=71959

Purchased my dream property on Vancouver Island in July 2018. Got out of the city finally, and picked up 5 acres of forested land bordering an ecological reserve.

Prior to purchase the plan was to find land and build, but land is scarce. Found a place already built that ticked every box. Including shop space. In this case, there are 2 x 400 square foot workshops. This is the tale of the metal shop.

The metal shop is a small 20'x21' detached double garage. Good thing that no cars park in here! The 8' ceilings meant that it would not be the wood work shoppe. (can't stand moving wood stock around with low ceilings)

Move in day was a mess, and the house took priority for a little bit, just getting everyone settled in. The chaos:

The previous owner wasn't too much of a handyman, though with this kind of property there are always things to fix. One of the many customizations I would have to perform before I was ready to use this shop:

After a few weeks of free time here and there, things started to take shape a little bit. The storage in my last shop was all built in, so it didn't move with me. The lack of storage hurts, and is related to not having the wood shop up and running for cabinet making yet.

Those that have read my last shop thread (linked above and here, will know the story of the free welding table. 750lbs of fun. Well in my wisdom (and haste) I pallet jacked the table into this shop upside down, and had to flip it on my own. It's slow going but I did it safely.

And Voila!

 

[Zengineer]

A bit of a panorama to start things off. Perhaps not high resolution enough to tell the whole story.

The inside of the doors were so dirty, moldy, and dingy. This was as much about trying to maximize the 4 little light bulbs in the shop (more on lighting to come) as it was about cleaning up. A quick bit of paint and a night and day difference.

First project in the new shop was another bench, this for my bench grinders and home built 2x72 sander.

This little guy has been with me for 20 years now, can't say enough good things, but some more oomph would be nice.

A shot of paint. Still haven't put a top on this. Wood or steel? Likely steel. Need to do that soon, and finish it off, lol.

 

[Zengineer]

Just have to say, these little Nissan jacks come in hand for so many things! This is me moving my fully loaded fastener cabinet. I move heavy stuff all the time, but I generally find a "smart" way to do it.

Was getting tired of the old abrasive chop saw, so have gone a different route. Favorable reviews thus far!

Working on a dining table build, a nice lightweight one.

I took this shot to represent the really poor light levels in the shop. 4 bulbs for 400sqft is tragic. (I had 8 in my last 400 sqft workshop and it wasn't superb) Lighting upgrade incoming... Also, P&W Model C from 1952.

Dipping my toe into LED lighting upgrades. 2 installed, 18 to go! (yes I did 20 of these Hyperikon T5 22w strips 4000K, $65 for 4 from Amazon)

Here I have just finished the one side of the shop, and am staring into the darkness on the other side...

 

[Zengineer]

One of the drawbacks with not building this shop from scratch (or closer to scratch, as in my wood shop) is that I didn't get to put electrical outlets where they make sense. So half of this shop has 1 outlet on the wall, which is far from convenient.

One step to mitigate this was through a Christmas present:

Lighting

The lights I chose were these https://www.amazon.ca/gp/product/B012ENQSSI/ref=ppx_yo_dt_b_asin_title_o01__o00_s01?ie=UTF8&psc=1 Hyperikon® LED T5 Integrated Single Fixture, 4FT, 22W, 2200lm, 4000K (Daylight Glow), Frosted, Utility Shop Light, Basement, Ceiling and Under Cabinet Light, Corded electric - (Pack of 4)

I think the photos tell a great deal of the story. I've done my best to make these shots representative of what you perceive when you are in the space.
BEFORE

AFTER

BEFORE

AFTER

So my impressions of this lighting solution. First off, it's about 140 lumens/sqft. Bright yes, but I'm at that point in life where my eyesight is soon to start getting worse, and I didn't want to have to redo this. It's bright, but comfortable.

With 20 fixtures spread around the ceiling, even thought this is a relatively low ceiling shop the diffusion is excellent. There is no glare. The only spot where more light may be needed is over the work bench, but due to the irregular shape of the shop in that area it means there isn't one directly overhead. I plan on installing another light there once I've build my cabinets.

The mounts on these lights are pretty cheesy. But they work pretty well actually. All in all that was the most unimpressive part of these fixtures, and they worked quite well in the end. I absolutely recommend these lights thus far, though they've been installed for less than a month now.

 

[sbosecker]

Zengineer,

Nice work on the lighting! That's a huge improvement.

Good luck on your future projects.

Best regards,

Scott

 

[1953mercury]

Really looking so much better, great job. The Pratt & Whitney is a beauty. Mike

 

[protegeV]

Very nice. I look forward to following along.

 

[turbowoodworker]

Subd. Thanks for all the detailed pictures.

 

[shirk]

Thanks for the detail on lighting. I have a 16x24 that needs more light.

 

[Zengineer]

Really looking so much better, great job. The Pratt & Whitney is a beauty. Mike

I agree there! It doesn't get used enough to justify such a nice machine, and it's a pain to haul it around (4700lbs) but it's not going anywhere!

Thanks for the detail on lighting. I have a 16x24 that needs more light.

I think this was quite an inexpensive and unobtrusive way to get more light in the space, and addresses the typical low ceiling vs. diffusion issues (generally made worse with LEDs) quite effectively.

I spent $300 on lighting roughly, but I think no matter what reasonable route I had gone with the existing space, that would have been exceeded to achieve these light levels.

 

[jeepinerdeep]

Nice place bud!

 

[sean Buick 76]

Looking awesome! maybe you should fab up an I beam from the roof to help move heavy stuff around? Or maybe an engine crane would be handy you seem to move lots of heavy stuff.... I am envious of this shop, it is going to be perfect once you get it all setup...

 

[casmurbax]

Very nice.

 

[Zengineer]

Looking awesome! maybe you should fab up an I beam from the roof to help move heavy stuff around? Or maybe an engine crane would be handy you seem to move lots of heavy stuff.... I am envious of this shop, it is going to be perfect once you get it all setup...

It's crossed my mind! At the moment what I have in mind is an I-beam and a crane trolley, supported at each end to the foundation. 1000lbs would be my target. (Very much like April Wilkerson's last video, the one they put in her dad's shop, here) However, with the low ceilings in the space (around 8') and how it's divided, I will have to choose carefully.

Even though it won't help me move the really heavy stuff (the P&W lathe tips the scales at a svelte 4700lbs) it certainly would help with all the 200lbs stuff (arbor press, anvil, big vice, etc.) and could be used to load and unload from my truck. May be a fun car and engine build in the future again too, who knows?

Definitely a good idea, and I'll document it if I decide to do it. For now, it's only going to jump to the top if I find a perfect scrap I beam.

 

[Zengineer]

Well this was a monumental day for me. After 20+ years of wanting a TIG I found the right deal on the right machine for me. The Lincoln Precision TIG 225. Perfect for me because it's a decent size which will do everything I do. AC and DC. Used it was affordable to me. And it's doable within my existing panel capacity. I would have loved an inverter machine but they are big bucks and rarely if ever come up on the used market.

Here it is:

Barely had enough reach on my little tractor to unload it, but it managed. What a backsaver this is! Even though the machine loaded like this is probably only 300lbs, why use brute force when you don't need to?

At home in the shop!

And all cleaned up. Have some bits and bobs on the way, just need to sort out my electrical a little bit and I'm ready to go.

 

[welder57]

Great find, good luck on your welding!!!!

 

[jeepinerdeep]

Nice machine find.

 

[sanddan]

I have the 185 amp version of that Tig machine. It's been a great unit to learn on. Only time I've maxed it out has been on aluminum, still did the job though. I did add a smaller torch since most of my work is around 125 amps, same size as a water cooled but air cooled.

 

[turbowoodworker]

I too have the 185 amp version. Now if I only knew how to use it

It is actually pretty easy and fun to use. Perfect for my hobbyist nature.

 

[don long]

That looks like my tig. I've used it a couple of times but not enough to get good with it. I use my mig much more often and am ok with it. Welding sheet metal is with a mig is what I learned to use 40 years ago.

 

[Zengineer]

I've TIG welded a fair bit over the years.... doesn't mean I'm particularly good at it though. Certainly rusty. Certainly still have a LOT to learn.

The Weldpak 100 MIG I have is pretty underwhelming sometimes, and while it does work for decorative welding, I have a couple more structural projects I want to do (lifting eyes for the tractor bucket for one) that I really want to be able to throw some juice into.

 

[rixtrix1]

Cool shop with some nice tools. Lights made a huge difference!

 

[90roadster]

I have 225 also and love it. Been good to me for 5+ years. Depending on how much alum. you do might want to consider torch cooler

 

[Zengineer]

I have 225 also and love it. Been good to me for 5+ years. Depending on how much alum. you do might want to consider torch cooler

Yeah I'll keep my eyes open for one, even though aluminum isn't really prevalent in my work. Then again, that changes project to project.

If the price is right I'll add one!

 

[Zengineer]

No shop updates at the moment (too busy working on projects... that's another discussion though). But I did do a "quick" video about my 2x72 belt grinder build if anyone is interested.

It's been a great tool, get one if you don't have one.

I've also got to see, the lighting upgrade in the shop worked out pretty darn well for video too. Still loving that improvement and would definitely recommend the product!

 

[Zengineer]

Today I've done a video of my metalwork shop, a good snapshot in time as I make progress! I've been in the shop for about a year now, have a long, long way to go to realize my vision for this shop, but we're getting there.

Check out the video here:

Enjoy!

 

[Bib Overalls]

I also purchased an Evolution metal cutting chop saw. Very pleased. In fact I was so pleased that I purchased their metal cutting skill saw. The only downside is the chips. They go everywhere.

 

[Zengineer]

Yeah I'm pretty pleased as well. I think you could surround the chopsaw area similar to how many do with their wood cutting mitre saws in order to contain the chips. Regardless, the cuts are clean and the material stays cool. A HUGE improvement over my old Makita abrasive saw.

 

[rattle_snake]

Nice shop.
As much as I love the Evo saw, getting a bandsaw to complement it was a great addition. They each have there pros and cons for a given task.
Just need me a belt grinder....

 

[Zengineer]

The latest project to be completed in my shop, both metal and wood shops had a part in this one!

My 8min long build video, please check it out!

This one took over 18 months start to finish. Phew!

 

[Zengineer]

Nice shop.
As much as I love the Evo saw, getting a bandsaw to complement it was a great addition. They each have there pros and cons for a given task.
Just need me a belt grinder....

No metal bandsaw for me yet! But very soon.

The belt grinder is a game changer. I made a video about mine, but can sum it up with get/make one NOW if you do any metalwork at all. I use mine non-stop, and if I was starting a new shop from scratch it would be right there with a drill press as one of the most important tools to have.

 

[rattle_snake]

No metal bandsaw for me yet! But very soon.

The belt grinder is a game changer. I made a video about mine, but can sum it up with get/make one NOW if you do any metalwork at all. I use mine non-stop, and if I was starting a new shop from scratch it would be right there with a drill press as one of the most important tools to have.

Now I'm shopping for one again... You're an enabler, you know.

I buddy lent me a HF belt/disc sander he got from someone else, as he had no place to put it. At first I didn't want it but reluctantly took it. I build a stand for it and now and use it daily, way more than my bench grinder. It's performance is way below a belt grinder, but I get the usage model now.

 

[zmotorsports]

Subscribed.

Good looking setup thus far.

 

[Zengineer]

Now I'm shopping for one again... You're an enabler, you know.

I buddy lent me a HF belt/disc sander he got from someone else, as he had no place to put it. At first I didn't want it but reluctantly took it. I build a stand for it and now and use it daily, way more than my bench grinder. It's performance is way below a belt grinder, but I get the usage model now.

2x72 or larger! But I built mine for $500 or so. Unless you have $2-3k kicking around I'd recommend building your own.