Post Project Evaluation – May 2020

While I was making my printer cabinet, I noted several things I wanted to address when I was done. From storage in the workshop to holes in my arsenal or skills lacking, this is going to be a lengthy post talking about all of it. Perhaps this will be a series going forward, which is why I added the date to the title. I have done tool wish lists and shop goals in the past, this is meant to be a complete comprehensive review of myself and my shop after a major project.

By far the biggest problem during this build was the amount of junk on any and every horizontal surface. Some of this was cutoffs from either the walnut hardwood or the walnut veneer plywood. Some of it was tools that I was between uses. Some of it was things in the shop that didn’t have a great home or no home at all. The first thing that I had to do was address this problem, as going forward I would have even bigger projects and more potential for clutter.

The cutoffs during a project should be addressed as they happen. I need to do a better job of identifying what is usable to keep, and what simply needs to be discarded. In particular, unless the plywood is of a certain size, toss it. Hardwood or softwood should be sorted and stashed away if there is room. If not, or the piece isn’t usable, into the scrap bin for burning or trashing. Don’t let it pile up on a surface. This was egregiously bad on my workbench to the point it was unusable. You can see it in the pic below.

Find homes for things. I can do a better job of making homes for things so that they have places to sit not on horizontal surfaces. I was moving some things around from tool to tool because they were constantly in the way. Things need to not be too good for their home.

Don’t be afraid to re-evaluate layout, processes, anything if it comes up. If a problem prevents you from accomplishing a goal, that problem needs to be addressed in some form. These are all general things, it’s time to dive into specifics I saw, and either addressed or in the process of doing so. I’ll do this in a clockwise fashion from the door.

The table saw’s function was mostly fine, although I did find two problems with dust collection. One, I wasn’t getting a lot of suction from the bottom. I filled some additional gaps with duct tape and seemed to get a bit of suction effect on the zero clearance insert. What’s left is to address dust collection at the guard – the hose is too long and bulky for most cuts and shifts the splitter to the fence side trapping the outfeed. I want to come up with something similar to what I had with my old table saw that is a fixed overarm dust collection tube. I’m still evaluating my options here. I also found that I have never made a dado cut on this table saw, and when I went to do this for the panels, I could not because I had no appropriate insert. I ended up ordering a metal insert from Lowe’s made for this saw. Eventually I will make a bunch of insert blanks.

The drum sander is one of the newest additions, along with the bandsaw. It worked well, but I did notice next time I go to use it I need to adjust the tables a bit upward. Trying to use the oscillating sander stored underneath, it became quickly clear that this had to change. The sander had to come completely out to use, and there was some contortion involved. After the project I found a home for it under the lathe, and now the large grinder sits there, temporarily.

The bandsaw is just fine, but I do need to make more dust inserts, because each time I forget to set tension one breaks. The dust collection hose is a bit bulky between the saw and the MFT, but that’s a low problem. No issues with the parallel clamp storage, but perhaps I could improve the spring clamp storage.

The MFT sysport can be a bit of a pain to get to the air tools, and I’m considering relocating that systainer. Not sure where yet, because it isn’t something I need very often, but when I need it I shouldn’t have to move a bunch of other stuff. The rail also tends to hand on the bottom of the TV when moving, so I need to consider moving the TV up, if not also over a bit to cut down on glare from the light directly in front of it.

There are a couple of issues I found with working at my MFT sysport, and they involve the Festool CT vac mounted underneath. One is that I need to improve the boom arm by making the hose both better attached to the arm and able to easily be removed. One is that I want a better way of activating the vac without having a tool attached. One is that I want to directly attach non-Festools to a power source supplied by the vac (which would also address the second point). I did order two conversion kits, which one I will use on my Dewalt 611 palm router. I’ll post up about that when/if they arrive. That would reduce a lot of need for having the vac come on without a tool, except for the TSC 55.

The workbench area will be greatly improved just by keeping it clear during a project and available for hand tool work. I am planning on moving the hand tool cabinet over closer to the corner. What this will do is allow for taller pieces and better access to my end vice. I am worried a bit about being able to access it well, and it may be that I have to rethink that. The under-bench cabinet should be redone at some point, as whenever I access my socket set it is gouging the MFT sysport with the drawer slide. Also, the drawers were not specifically made for this and often fall off track. This storage can be better used.

The miter saw/systainer cabinets suffered greatly from junk. My spare batteries and the Bosch chargers littered the surface. These have all now found a home, including wall mounting the Bosch charger (and I’ll mount the other one exactly the same way). The charging location may move based on need and convenience. I need to do a better job keeping the systainer area clear of larger boards and ply pieces, as I was continually moving items to get to different tools. This will be critical as I continue to add more and make all the drawers double depth. The upper cabinets need to be used more efficiently, and I’ve started this process by moving over all my finishing supplies out of the previous cabinet. Two part epoxy, glue, and other finishing items were adding to the clutter. I will be considering adding to or redesigning the cabinets to fulfill more needs as conditions warrant. The miter saw is awful at capturing dust, and may or may not be completely accurate at times. I am going to try to resolve some of the dust issues first before I follow through with a replacement. If I do replace it, the Kapex will be the choice. It is expensive, and it comes with a couple of other drawbacks, but it is the only thing I’m considering that actually takes dust collection seriously.

I used the jointer and planer pretty significantly during this project, and am thankful I addressed the jointer and tuned it up. The only issue I have with it is one of capacity, and I don’t think I can upgrade to an 8″ jointer in this shop. The planer needs to be upgraded with a helical head, but more importantly the height needs to be addressed if possible. Using the planer at the height it is was very uncomfortable, but I’m not sure I can fix that effectively. It is as high as it is to accommodate everything else in the shop. I will be looking to see if the cart can be higher and sit under the right side of the table saw, or if I can try again to combine the drum sander and it into one stand. That would be the ultimate space saver if it is possible.

No issues with the lathe, it really hasn’t been used since it came into this shop. I do need to adjust the dust hose there as it comes out right where the headstock is. Move the blast gate up is the most likely outcome, or it is possible I could actually move it down and to the left of the headstock. To allow the osciallting sander to live under the lathe, I had to remove and disassemble the drawer holding the turning tools. They are now just sitting on the lathe table, which is fine for now. Above the tailstock I made a short shelf to hold the hollow chisel mortiser. It was getting in the way on the floor and falling off the drill press base when it was there. It is situated behind the drill press head and think will be a great spot if the shelf holds. May need to make it slightly bigger.

With the drill press base clear, I made a small cabinet to store drill bits. My forstner sets were floating around a bunch and getting in the way, and making a spot for them. I’ll be adding a bit more storage in this spot as needs come about. This would be a great spot to add some light storage on the side for table saw accessories, because that’s something I neglected to mention above.

As far as upgrades or needs go, specifically evaluated during this project and a very small one after. I don’t have a great way to address full sheets of ply. I have to crosscut everything first, unless it is some 1/8″ material. Then I can rip it on the table saw but it flops around everywhere and doesn’t want to clear my workbench. It also isn’t that accurate.

So I need to find a solution for rip cuts, and I’m starting out by purchasing some guide rail connectors. This is a trivial expense compared to a long rail, and much easier to store. These will be here this week, and I can’t wait to test them out. The first project with them may be a new workbench cabinet. If they don’t work as well as I’d like, I’ll sell them and buy a 118″ rail and figure out a way to store it. If they do work, I may buy one more 55″ holy rail so that I can swap between crosscuts and rip cuts easily. The other aspect to this is that I need to have a wider surface to do these outside the shop cuts on, the 4×2 table I have outside is simply not big enough for this purpose. I was thinking about getting some nice sawhorses to set up occasionally, but the price shot up before I could pull the trigger. I’m hoping to work on the area outside of the shop in the next few weeks to have a level surface behind a retaining wall. Unknown when a finish date on this might be, it depends on how hot it gets and how difficult it is to dig the trench for the bricks. I also purchased a TSO rail square so that I can ensure my sheet goods come out square. I will be attempting to redo my parallel guides, as I will need those when I make the tall bookases.

I desperately want to upgrade my miter saw, but $1500 is a lot of money for some marginal difference and some better dust collection. I’m going to attempt to address the dust collection first with some scrap. If that doesn’t work, then I might address this need.

I have a few holes in my arsenal at the moment, and the struggle is determining which ones to address first. My block plane is just about destroyed from rust from dried glue on a previous project. I am going to try and fix it for continued use on plywood, but I finally ordered a Veritas one and a couple of accessories for it. It would have been very handy to use for chamfers on the printer cabinet. I discovered I did not have a 1/4″ shank roundover bit for my palm router, I addressed this yesterday by grabbing one from Rockler. I also replaced my broken router collet wrench last weekend. I’ll be ordering a new chuck for the old Triton router and perhaps it can be a second router table somewhere.

There are other holes that I want to address soon, but I honestly don’t know what the importance and order should be. I want the larger Domino to make larger projects, but I don’t have anything on deck that needs it. Down the road, yes, which makes me think it can wait. I don’t have a way to strip finish or paint, which is where a Rotex 150 would come in. Again, though, not immediately needed. What would be nice about this though is that I already have most of the paper I need for it. I also cannot spray any finishes or paint without a sprayer, and I actually might be leaning toward filling that hole soon. I am debating making our new kitchen cabinets, and being able to spray them would be a huge time saver. Not sure I want to be building them, though. I could also theoretically get a similar finish with a cheaper paint gun.

It’s a bit tough because I think I’m too the point where I don’t have too many pressing needs, and it’s all about strategy right now.


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