Opportunity to build a shop - I know nothing

[jschoolcraft]

I'm moving to Wilmington, NC and I'll have an opportunity to build a shop and am hoping to figure out all the things I don't know about building one that would have been useful for folks that have already gone through the process.

I think I'm targeting something the size of a detached 2-3 car garage with power, water and conditioning. It'll be in my backyard so I don't think I want/need a bathroom.

I think I want to separate a compressor and dust collector from the main shop (have a wall between them) and maybe have storage or just an awning and shelves for wood storage.

I do some flat work.

Happy to be pointed to threads, hear what you would have done differently, wish you would have known, or absolutely would do again if you had the chance.

 

[GaryMGg]

The Woodnet forum has many members who have built shops.

I built my own—16' X 32' with 11' walls.

There are books available which discuss shop layout and efficiency.
R.j. Decristoforo wrote numerous books on DIY construction which are classics.

It's useful to create a scale model of all your tools and layout the shop on paper. Make paper rectangles for each tool footprint and move stuff around to see how the space works.

I put transom windows all around my shop from 8' to 11', creating lots of natural light.
I put the receptacles about 4' up, making them easier to access. Lots of separate circuits. I also have 6 — 8' double tube LEDs on 4 individual switches. This allows me to turn them on and off as needed.

My shop is offgrade on piers with a plywood floor. It's much more comfortable than a concrete floor!

Be sure to allow space for your wood hoarding—it's gonna happen!

You'll probably have to pull a permit.
So, you'll want to know what the local building codes are.

I do mostly flatwork myself.
I put a pair of 4' wide (each) doors in front of the table saw and a single 32" wide door behind it in line with the front doors.
Opening all 3, I can rip any length board when the need arises. I've used it more than I expected.
The tall walls makes it easier to handle long boards as well.

If I think of something more, I'll post more.

 

[mredburn]

I recommend quad outlets every 4 ft on 20 Amp circuits 50 inches off the floor. along with dedicated 220 outlets for your specific machinery.
I also laid out my shop to scale before ever building it so I knew where everything would fit and how work would flow.

 

[GaryMGg]

Also, put as many tools on locking casters as feasible.
Even with the correct layout, there will be occasions where you need to move something.
My second shop is a converted garage which is rather small. With almost everything on casters, I can make space for certain cuts which wouldn't work if nothing were mobile.

 

[NJturner]

Plan on one thing - you will change the shop layout on a pretty regular basis as your interests and projects change. So be sure to make things flexible to allow the change. Cleat walls, rolling tools possible on a good smooth floor with few transitions, good lighting that is throughout the entire shop, power more places than you imagined, including the ceilings (drop cords or air circulators), and temperature/humidity control. Try and design with the least amount of trip hazards - cords on the floor as an example. Think about your use of flat space - as a work area or will it just be for junk collection. I believe lots of things for good design are more than just where to put my tablesaw!

Kevin

 

[Ted iin Michigan]

Yikes! You just got some great advice (above). My shop is also an outbuilding that's 24'x32' with 9' ceiling. I've longed for a larger space but that's mostly because I "collect" stuff. Periodic purges help. The only thing I'd suggest reconsidering is the bathroom comment, especially since you're already going to have water. That being the case - you're digging a trench - then why not? I'm on a well & septic system and it is sooo nice to not have to pee in a bottle or run into the house in winter. Va isn't Mich but still...
GOOD advice above.

 

[bugradx2]

I seem to recall at some point in the last 2-3 years someone asked people to show photos of their shops. You might want to search for that. If I had recent photos of my shop I'd put them up here.

You mention conditioning, I'd make sure you add heat and not just air. I agree that a quick powder room is not a bad option either. Heck, you could use a slop sink for the regular sink and make it multipurpose.

I agree with the compressor and dust collector having their own space but I might try to put them in an insulated space in the shop, you'll probably be more likely to change the dust holder and do any servicing you need to do that way. It will help keep insects and larger critters out too. I'd recommend making that space somewhat modular so if you go to a larger dust collector it's easier to do so. I've also got an air cleaner (Wen brand, maybe $125 or 150?) that I use that has impressed me with how good a job it does.

Gary's idea about a scale model of the shop and equipment is spot on, that will let you play with things. Reading a few articles or books on shop design may give you some ideas on what tools could group where to put them will help too.

I have a purpose built shop that's pretty small so everything in there is on wheels and my dust collection hose is on the floor and moves from tool to tool. That's not ideal but it pretty much reaches everything and I don't have to run piping in the ceiling so I've gone with it. The wheels help to keep things out of the way if I don't need them. The only thing that isn't on wheels is my shop/assembly table.

I do think reviewing or checking on your local building codes is smart. I'm in the Chicago area and everything here has to be in conduit which is not how a lot of the country is. I actually have come to really like it. It's really darn hard to drill through anything in the house accidently. Speaking of electrical, add more than you think you'll use. I mean both outlets and breakers. I have a pair of 20 Amp circuits feeding 1/2 the shop each with a third 15 amp circuit feeding the outlets in the ceiling. A fourth does hit one pair of outlets but it was a matter of convenience because some other electrical for some other sections of the basement at the same time. I wish I'd put another 1 or 2 outlets in the ceiling. All the wall outlets are countertop height so if I want to add counters or cabinets the electrical is already there. I use the ceiling outlet above my shop table all the time for sanders and other tools. Generally speaking, wire your shop you like would a kitchen, a boatload of outlets. My shop is in the basement and I do have the first outlet closest to the breaker box set up with a GFI too. It's code and is a little more expensive but it's nice having the security of that too.

Going from electrical, lights, lights, lights. This is also part of wishing maybe I'd done a couple more ceiling outlets to plug in the lights because I probably need to add one more light bank to one area of the shop. My lights are on a switch which is super convenient also.

I found free cabinets from someone who was renovating their kitchen in the neighborhood. I can't recommend that enough, call a couple builders, someone is going to be flipping a house or doing a kitchen and would love you to come haul off the cabinets. Bonus points if they have the drawer systems halfway up the cabinet to double your storage. Mine came free with the laminate counters. I think it took me longer to get them into the basement than it did to actually put them back together and secured to the wall.

A buddy of mine has a shop that is mind boggling. He's put in storage for sheet goods and a large "cubby" system for smaller pieces, pen blanks and bowl blanks. It's very nice and everything is off the floor.

I've tried my best to make sure all the flat surfaces in my shop are the same height so the various surfaces can serve as outfeed tables for the tools.

I built my shop table MDF & 2x6 construction lumber following a plan that Woodsmith published and featured on the TV show several years ago. It's been a phenomenal table. I went above their plans and added a tail vise and end vise with dog holes too. I use them all the time.

I left the interior walls of my shop as bare studs so I could add shelves between or across the studs quickly and easily as needed. It also helped with my code inspector (and cost) because if I'd drywalled them I would have been forced to do firebreaking and a bunch of other stuff. Technically, as far as the village is concerned for taxes, the space is a storage room because it does not have finished interior walls and not taxable. The inspector and I laughed about it because it's got more electrical than any other storage room either of us have seen. If you decide to enclose the walls, make sure you take a TON of photos of the walls and structure before you enclose them. Take the time to print them and stick em in a cheap scrapbook. We built our house and I can't tell you how many times I've used that book hanging stuff or doing other things.

Eventually, my wife and I will sell this place when we want to go into a ranch house or move someplace else. I did the work with the building permits and approvals because it makes my shop a non arguable space. It's got a permit, fully inspected and approved.

 

[jttheclockman]

The first thing is to take stock in your life. Do you have the funds to outfit a full working shop comfortably? Is this building going to be strickly a work shop? How old are you and how healthy? Then take note of your service in the house because you will be adding a sub panel. Will you have to upgrade the service? Again another expense. Who will do the construction and are they reliable? I would not ever put a shop on a plywood floor. It would be a concrete floor. This way the building can be converted if need be by future owners to a garage or some sort. Take inventory as to the tools you have, the tools you would like and tools you need to do whatever you do now as a hobby. Your hobbies will grow and change with time. Saying you want to make furniture or large projects like that, is fine but look at the entire picture. What you plan to do with them or with anything you make? Will you get into sales or custom work. I say this because now time becomes a factor and the tools change accordingly. You will not be building furniture with hand tools and also selling them. You would be out of business in a month. Too slow. Look the plans over and look them over again when you settle on the idea. Are you dedicating entire building to a shop or other functions and plan for that. Take your shop dimensions and now lay out your tools with a good work flow just as if done with a kitchen. Make a full size tablesaw the main focus of the shop and build around it. Dust collector for a shop like that needs to be large capacity. Forget roll around dust collectors. More headaches than needed. To me I would do an underground dust collection to the tablesaw as well as power to it. All other tools line them up against a wall with ample space around to work comfortably. and safely. Dust collection can easily be hung close to the walls and electrical easily done on walls. Look into a finishing room seperate from a shop. Dust and fumes need to be addressed for that.

As mentioned many books on this subject so check them out because they help designing dust collection as well and other thing. Adding air and heat jumps price up of build because materials change to accomindate. Good luck with the adventure. I always envy those that have full shop space as opposed to a basement shop as I do. I am too old to redo any project like that in my life. Keep us up to date as we all like to spend others money as well as marvel it would we would like to have.

 

[Mortalis]

Now that my new shop has one I highly recommend having at least a toilet and a sink.
Walls with OSB or some type of wood paneling for mounting stuff to.
Plenty of outlets. I had my new shop (converted two car garage) wired for shop purposes I am wishing I had twice as many outlets.
Cabinets with laminated tops. I watch at Lowes and HD for damaged cabinets and pay 50% or less asking price and then I just repair or use as is. I lay them out and then cover them with laminated tops. Sometimes they can become a junk collection area but having the long run of top space is nice.
Overhead lighting. The electrician that wired my new shop recommended LED strip lights and I'll tell, what a difference from flourescent. Have them mounted wherever you lay out your stations of work.
Dedicated, closed off area for Dust Collection with an exhaust to the outside.

 

[Woodchipper]

Good luck as you have seem there are lots to take into consideration from initial cost to electrical service (can't have too much). Also, do you anticipate adding any other pieces of power equipment?
Good luck with the move. I'm jealous as you will have access to some fresh seafood.

 

[Jarod888]

Even though it will be in the back yard, is reconsider having a bathroom. It is much easier to clean up a bit before going into the house and worst case scenario, if you get something in your eyes or face, you are that much closer to washing it out / off. Plus, if you put in a slop sink, you'll have an easy place to wash out brushes, rags, etc.

I would say plan on a minimum 100 amp service, ideally 150 or 200 amps. Keep your lights on a separate 20 amp circuit that nothing else is attached to.

Each wall should have 2 20 amp circuits for normal outlets. Ensure you have a outlet every 4-5 feet. Also, put a couple of outlets up high, near the ceiling. You never know when you'll need to plug something in up high. Have a couple of dedicated 20 am circuits with just one outlet for specific tools.

Run air lines in the walls and add a couple of manifolds with drops on each wall.

Insulate the walls. Instead of using dryway for your wall covering, use 3/4 inch sandiply for the walls. Prime and paint it a nice neutral color, like an off white or light tan / yellow. This way you never have to worry about where you are going to hang things.

Look up "doorbinets" on YouTube. Essentially, for your upper cabinets and some lower cabinets, instead of shelves, you install vertical pull outs. You can gain an enormous amount of storage space that won't become a black hole, like cabinets can.

I'm not a fan of having things on casters, I think they just introduce inaccuracies that aren't present with solidly mounted tools.