Little Shop of Horrors no More

While my wife and I wait to be permitted to see each other in Ireland, and while what we hope are the last days of our wait for a green card pass, I continue to work on my shop.

I finished my belt grinder cart. Photo below. It’s almost as great as it looks.

Is any project ever really finished? I still want to put some kind of arm on it to hold a shallow container of water below the 2″ by 72″ belt. It will catch sparks and keep crud out of the drawers.

Today I have been emptying boxes that have been on the floor since 2019, when I moved my big tools up here. I am also getting stuff ready to throw out. As I work, the shop gets bigger and bigger, and my ideas about building a new shop seem more and more ridiculous.

My next project will probably be shelves.

I have a huge 4-tier 4′ by 8′ set of shelves against one wall. I am not happy with it. It used to have the long side against the wall, making it very difficult to use because of the reach. Now both long sides are exposed. It’s still not great, because it juts out into the garage and takes up too much room.

I figure it has almost 128 square feet of storage, not including the floor. I would like to create a similar amount of shelving on the walls. This would open up the center of the shop.

I got an idea from Jamie Hyneman from Mythbusters. You would think a person like me would be a big fan of the show, because it’s all about tools and a sort of engineering, but I’m not. I don’t have the attention span for it. It drags a lot while they’re building things and explaining. I’m always thinking, “Come on man. Blow something up.”

Also, the chemistry of the hosts is somewhat off-putting. Everyone knows they don’t like each other, and it shows. When I watch, I always feel like Hyneman is trying hard not to sock Adam Savage in the mouth, and while I can see how Savage would get on a person’s nerves, I think most people would get along with him better. Just a guess.

Anyway, Hyneman’s primary business is in a terrible building which is about 100 feet long and 12 feet wide. I assume he must have gotten a great price. To cope with the shape of the building, he created his own shelves. They cover one wall. He could have gone out and bought prefab shelves and attached them, but they would have been expensive, and I don’t know if anyone sells appropriate shelves. His ceiling is very high.

He got himself some 1″-square tubing and welded it into a system of shelf supports. It’s brilliant. He has vertical tubes which appear to be about three feet apart, and he welded horizontal tubes to them to hold the shelf material. I don’t know what the material is. Probably plywood.

As he pointed out, welding is extremely fast compared to drilling and screwing, and square tubes are very easy to weld together because they have a lot of flat surfaces. I don’t know what tubing costs right now, but steel prices have been dropping, so it may be possible to get 12 feet of tubing for around $10. If that’s true, I could put up a framework for maybe $120. Two shelf units 9 feet long with 4 shelves each would give me 108 square feet of shelf. It would be better to use 6 shelves per unit, because shelves that are too far apart are wasteful. This would give me 162 square feet.

Plywood is expensive, but not like it used to be, and I could cannibalize the plywood in my existing unit.

As part of the project, I would like to get a small shed for materials. Then I could keep more tubing and plate and so on. Grabbing stuff you already have is always better than driving to buy more.

The shop has gotten so much bigger, I am once again able to park my garden tractor and utility cart in it. The big tractor is too much to ask for, but with all the new space, I should be able to forgo a new shop and put up a smaller shelter for the tractor and a few implements.

Guess I better get back out there. Those dead roaches aren’t going to sweep themselves out into the yard.