For
most of us, a big shop is only a dream. Too often, we’re forced to build
our ambitious projects in a shop fit only for building
birdhouses.
In spite of its postage-stamp size, you can still churn
out dining room tables, kitchen cabinets, library shelves and other major
projects. The keys to making big things in a little shop are organization,
out-of-the-way storage, and nesting or collapsible work
surfaces.
If your shop and tools are small but your dream projects
are big, here are some ideas that will help.
Air-Compressor Loft
Click image to enlarge.
Air compressors—even small ones—take up a lot of
valuable space. To preserve every square inch of floor space, build a little
corner shelf overhead. Nestle your compressor into a corner of the floor and
measure the size of the shelf you need to fit it. Leave an extra 2 in. of room
at the front where you can screw on a 2x2 lip to “corral” the
compressor so it won’t walk over the edge while it’s running. Then
measure the height of the compressor to determine the proper distance from the
ceiling to the shelf so the compressor has enough clearance.
To build the shelf, start by fastening 2x6 ledger boards
to the studs with 5/16-in. x 4-in. lag screws driven into each stud. Screw down
a chunk of 3/4-in. plywood on top of the 2x6s for the compressor floor and
another chunk on the underside for a storage shelf. A strategically placed
3-in. hole makes it easy to drain the tank from underneath. To really complete
this air tool station, solder 1/2-in. copper tubing and attach it to the
compressor with a swivel “snubber” hose. Connect an air hose reel
for compact hose storage for long-distance needs and a curlicue-style hose for
air-at-your-fingertips bench work.
Pay for Service
Click image to enlarge.
A small shop can’t handle everything. Most
stationary tools are expensive and space hungry, but they can save hours of
time over smaller tools like hand planes and belt sanders. When you need an
occasional helping hand, find a cabinet shop that’s willing to plane,
sand, shape and rip the work that you bring in. For example, the wide belt
sander in the photo will do a perfect job of leveling a glued-up tabletop in
minutes—and you can usually have it done for under $20. A friendly
relationship can also pay off in terms of advice on things like joinery
techniques and as a source of raw materials or hardware.
Folding Assembly Table
You may not have room for a permanent assembly table, but
you can always clear a spot for this temporary folding one.
Buy a pair of collapsible sawhorses. Screw an old or
damaged door (lumberyards often have rejects at rock-bottom prices) to the top
of the horses. You’ll have a large workspace that folds up and takes very
little room to store. Screw two 1-5/8 in. drywall screws up into the edges of
the door at the end of each horse. The table will set up in about 60
seconds.
Ceiling Drawers
Click image to enlarge.
Eke
out every cubic inch of storage in a basement shop with pivoting boxes that
hang between the ceiling joists. When a drawer is down, you have easy access to
its contents. Use glue and 1-5/8 in. drywall screws to hold together the boxes,
then customize shelving for whatever you want to store.
Make the width about 3/8 in. narrower than the cavity it
fits in and use double-nutted 3/8 in. x 3-1/2 in. carriage bolts for the two
pivot points. Two plywood cleats pivot on 3-in. screws to hold each drawer in
place in the “tucked” position. The drawers are perfect for
anything you only need occasionally. But be careful to keep contents relatively
light so you can safely open and close the drawers. It’s definitely
not the place to store your
anvils.
Peg-Board Shelving
Click image to enlarge.
Panel your shop with Peg-Board instead of drywall or
plywood and there’ll be no shortage of space to hang dozens of hand
tools, no matter how small your shop is. Homemade shelving that’s specifically for Peg-Board
takes the concept one step further. Use 2x4s and 1/4-in. L-hooks to make the
shelves. Chamfer the top back edge so the shelf can be tipped in and tighten
the L-hooks for a snug fit against the Peg-Board.
Predrill the edges of the 2x4s with a 3/16-in. drill bit
and about every 6 in., screw in threaded 2-in. L-hooks to match the holes in
your Peg-Board. These shelves are surprisingly strong and can be sized to fit
your specific needs.
