Recycled Tool Stand

Ten years ago — not long after we moved into this house — my younger broth­er and I built a pair of work­bench­es. I designed a “tall” work bench for stand­ing and a “short” work bench that I could sit at (aka, a desk). The idea was that I’d do elec­tron­ics or oth­er work at the desk. How­ev­er, “near wood­work­ing tools” is a pret­ty lousy place to do sol­der­ing , etc. and this end­ed up just being a place to pile scraps and store my drill press, band saw, and pow­er sander. Unfor­tu­nate­ly, to use any of those then, I had to haul it out of the cor­ner and put it on anoth­er space. They’re not ter­ri­bly heavy but none of this was ide­al. So I had decid­ed I’d tear out the “low” bench and put rolling tool stands in that space. If I’m going to move these tools out to use them, it should at least be eas­i­er to do!

Thurs­day morn­ing, I just so hap­pened on Face­book to catch that my neigh­bor post­ed he was giv­ing away an old rolling stand. It looked per­fect so I drove over (two blocks away) to grab it. Pret­ty quick­ly though I real­ized this was for far larg­er tools than I own.1 I could­n’t even shut the door on the Pilot! For­tu­nate­ly, Angela was out of town so she did­n’t need to park in the garage. Yes­ter­day, I tore out most of that “low” bench in order to be able to park the stand in place. You can see that it took up almost the entire 4′ x 3′ space! Those slant­ed legs were fine for a very heavy piece of equip­ment, but my Ryobi band saw and Wen pow­er sander weigh maybe 80 lbs com­bined. I did need to bend one of the cast­er mounts such that it was lev­el with the oth­ers. This would­n’t be the last time I got to bend some met­al on this thing.

He must be very tall to have tak­en the pic­ture at that angle!

So I knew I want­ed to re-tool the stand such that the legs are ver­ti­cal. I gave it some thought and real­ized that I could piv­ot the legs about one out of the three bolts that con­nect each side of each leg (i.e., two bolts on each leg — one for each con­nect­ing side). I had mea­sured out and cut a bot­tom shelf from the “low” desk’s MDF sur­face so I had some­thing to align the legs to. Then I could just use my lev­el and speed square to get the leg align­ment. I used a white paint mark­er to mark the four new holes and num­ber each of the points so I could re-attach them (nom­i­nal­ly it would­n’t mat­ter, but it just helps to reduce error when things oth­er­wise don’t align because noth­ing’s “nom­i­nal”).

After remov­ing 2/3 of the leg bolts, I could rotate the legs to ver­ti­cal

I used the drill press and my step bit to drill the holes. Drilling steel is sig­nif­i­cant­ly more dif­fi­cult than drilling alu­minum (which can be gen­er­al­ly cut with wood­work­ing blades or bits). I recent­ly read Adam Sav­age’s book “Every Tool’s a Ham­mer” in which he has a chap­ter titled “Use More Cool­ing Flu­id” and, man, is that every sound advice for cut­ting steel. I typ­i­cal­ly call it cut­ting flu­id, but giv­en the amount of smoke I was gen­er­at­ing, it was def­i­nite­ly get­ting hot. Also, unlike alu­minum, steel is going to have burs that need to be filed off, even when cut­ting with a step bit. So I had to clean up each of the six­teen holes drilled.

Always use lots of cut­ting flu­id when drilling steel

I got the legs re-assem­bled and cut a top sur­face (also cut from the old bench’s MDF sur­face). I did have to replace a few of the bolts with spoiled threads but I hap­pened to have some spare 1/4″ bolts & nuts. It was at that point that I real­ized that the sur­faces of bent steel that were for­mer­ly par­al­lel to the floor were now about 10° out of flat. Enter the 5 lbs sledge. I basi­cal­ly whacked the hell out of the top lip all around until the to sur­face lay near­ly flat. Using some screws through the mount holes then got it nice and lev­el.

It may be only 5 lbs, but I wore myself out swing that ham­mer today

The cast­ers are the thread­ed bolt post type. If you’ve nev­er seen these before, please know that they are the worst. The end of the thread­ed rod is some weird star thing (no, not a Torx bit) which you can­not hold and just spins with the bolt. So, there’s no real good way to loosen a stuck nut — of which I had two. My design required that these cast­ers come off so that I could use them to also mount the bot­tom shelf. So, some Liq­uid Wrench and some vice grips to hold the thread­ed rod (which mess­es up the threads some, but was­n’t impor­tant as that’s where the shelf now sits), I pre­vailed.

I absolute­ly love Vice Grips. I used those a lot on tak­ing all these bent pieces of steel, too.

I final­ly drilled some holes in the cor­ner of the low­er shelf so I could sand­wich that shelf with the leg bot­tom and the cast­er nut & wash­er. I had to use the sledge to some­what flat­ten out the base of each leg. Oth­er­wise the cast­ers would all be at a tilt towards the cen­ter of the cart and it would be mis­er­able to move around. This ham­mer­ing allowed me to get the nut start­ed on the cast­er thread­ed rod. I could then tight­en it enough to make the entire thing stur­dy again.

Hard to believe that’s the same cart! It fits per­fect­ly and is exact­ly what I need­ed.

So, this was a sim­ple adjust­ment that took me about five hours of work. I could­n’t be hap­pi­er with the results, though. It rolls smooth­ly, is plumb and lev­el, and fits per­fect­ly into a tight area. I may put anoth­er shelf into this (I still have plen­ty of left­over MDF!) so that I can store sander belts, band saw blades, fence, etc. But for a project that I did­n’t have to buy a sin­gle item for, this is exact­ly what I need­ed for this space.

  1. He has con­vert­ed on bay of a 3‑car garage to a very nice wood shop with nice pow­er tools. []

Battery Charging Station

This is a small project I came up with an evening last week after clean­ing up my shop bench some. I’ve always just sat my bat­tery charg­ers on top of the bench area, but they take up pre­cious space there. After get­ting anoth­er Ryobi quick charg­er recent­ly, I fig­ured it was time to make a ded­i­cat­ed space for these.

Small set of shelves for bat­tery charg­ers and bat­ter­ies

There’s no short­age of shop projects for this same pur­pose, but it seems that most folks are ok with putting their charg­ers on a shelf semi-per­ma­nent­ly. I fig­ured I would need to occa­sion­al­ly get the charg­ers off the shelf as well. So I built in a small chase such that the cords won’t inter­fere with the French cleat sys­tem and can eas­i­ly come out.

The dimen­sions of this project are very spe­cif­ic to the set of charg­ers I have (two dif­fer­ent Ryobi and a Bosch), as you can see here. How­ev­er, I’ve post­ed my set of plans below and it should be easy to change the dimen­sions for dif­fer­ent charg­ers. Just make sure to account for the pow­er cords!

My three charg­ers squeezed per­fect­ly into 1′-5 1/2″ by 5″

I used pock­et holes to assem­ble the entire project (edit — which was made entire­ly from 3/4″ maple veneer ply­wood I already had on hand from repair­ing my kid’s bed). 28 pock­et holes is a lot for some­thing this small. But with the back split as in this design, I want­ed to makes sure it was plen­ty rigid. I could have glued it up as well, but by the time got it all dry fit, I fig­ured that would be overkill. I can always dis­as­sem­ble it and glue it lat­er. The real trick with this was get­ting to all those pock­et holes. Basi­cal­ly, but the shelf fronts on first and then put the back/sides onto the shelves.

Yes, I put eleven pock­et holes in a 5″ by 17 1/2″ shelf

Anoth­er small thing that made this lit­tle project fun: my table saw sled. I had real­ly been dis­ap­point­ed in using it. I put a decent amount of work into get­ting it right but it just was­n’t slid­ing well. I’d sand­ed the run­ners down as much as could (more and I fig­ured there be too much slop). I just hap­pened to buy some paste wax today as I’d seen it men­tioned in some videos. It real­ly should be stressed more: put paste wax on your table saw sled run­ners! The sled glides along with very lit­tle force now and cross-cuts are a breeze!

My mas­sive table saw sled on my lit­tle Ryobi table saw works great after adding some paste wax!

So this was a good lit­tle project and went off with (almost) no mis­takes thanks to putting in some decent plan­ning and tak­ing plen­ty of mea­sure­ments of what I want­ed to store. I say almost, as the cut-out above the bot­tom shelf to accom­mo­date the AC adapter was ini­tial­ly cut with­out account­ing for the bot­tom shelf depth. Anoth­er quick pass on the band saw and it fit fine.

The after­noon sun creep­ing into my work­space

In case you can’t quite read those sheets on my rolling work­bench, here are my plans for any­one so inclined to build some­thing like this. One poten­tial mod­i­fi­ca­tion would be to put some han­dles (either hard­ware attached to the top of the sides or hand­holds cut into the sides) and a bungie cord across the front of the low­er shelf. That way, with just unplug­ging one cord, I could take all my charg­ers with me.

Shop Air Filter Installation

My garage is sort of orga­nized, but it’s cov­ered in dust. I knew it was get­ting bad and so I ordered a rel­a­tive­ly inex­pen­sive air fil­ter for shop spaces. I’d had my eye on the WEN 3410 3‑speed air fil­ter for a while. Home Depot has the best price for this item, but it’s rou­tine­ly out-of-stock. It came back in stock in Feb­ru­ary so I ordered one then. It arrived, I plugged it up just to make sure it worked, and then it sat on my work­bench for the past 6 weeks or so.

The WEN Air Fil­ter installed

I had pur­chased the nec­es­sary hang­ing hard­ware a cou­ple of weeks lat­er, but still did­n’t get around to hang­ing it up. You see, our garage has real­ly high ceil­ings (12′-6″) and the dinky 12″ chains that are packed in the box weren’t going to cut it. The instruc­tions state to hang it at least 7′ above the floor, but I’m pret­ty sure 11′ in the air isn’t going to cap­ture a lot of dust. I pur­chased some pre-punched angle and about 20′ of 300lb chain. But still, this all sat on the work­bench (ok, so maybe my garage is less orga­nized than I’d like…).

So, today I final­ly decid­ed it would the be the day to install this thing. And appar­ent­ly none too soon. My son want­ed to go over to his friend’s house but told me he did­n’t want to ride his bike because it was cov­ered in dust (he’s not wrong, but we got it down and aired the tires any­way).

My first time cut­ting steel with a cut­ting wheel on an angle grinder

So the angle I pur­chas­es was a 4′ sec­tion, and I need­ed to cut it in half. I also bought a cut­ting wheel for my angle grinder. This was actu­al­ly the first time I’d ever cut steel with an angle grinder. I did wear a full face shield but did­n’t cov­er my arms. The sparks were min­i­mal, but I would­n’t want­ed to have cut sev­er­al that way. I could have uses the same cut­ting wheel to cut the chains to length, but my bolt cut­ter was faster.

The first angel and chains installed (that’s a 9′ lad­der by the way)

After that, it was just a mat­ter of get­ting the angles lag screwed into the ceil­ing joists. I used some thread­ed quick links to attach the chains, just in case the unit start­ed swing­ing around. That proved to not be a prob­lem. Frankly, this was prob­a­bly all overkill to hang a 31 lb unit, but it’s room to grow if I need some­thing big­ger.

I had to add an exten­sion cord to get it plugged into the same out­let as my garage door open­er and my retractable exten­sion cord­By the way, the retractable exten­sion cord is one of the sin­gle best items I’ve got­ten for my shop. Between that and my rolling work­bench, it feels like hav­ing a whole new shop area.. Then it was ready to test. Admit­ted­ly, this isn’t a very pow­er­ful air fil­ter. At full speed, it’s 400 cfm. For­tu­nate­ly, that’s not enough to get it mov­ing hang­ing from hose 4′-6″ chains.

Air fil­ter and garage door motor shar­ing some ceil­ing space

I don’t yet have much of a sense of how well it works, but it gets pret­ty good reviews. I’ll put it to the test soon enough by tak­ing my air com­pres­sor to start blow­ing dust off of every­thing.