MarphodWoodShopImprovements

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My Ideas to Improve the Wood Shop

Dust Collection

  • We need to get automatic Dust Collection switches for, and installed on, anything that is set up to use Dust Collection.
    • Machines
      • SawStop 3, which is partially wired already as I understand it.
      • Both Band-saws
      • Both Sanders
      • Large Joiner
      • Planar and Small Joiner
      • Panel Saw
      • Router Table
      • Miter Saw and SawStop 5 already have auto switches.
    • Need to get switches that will trigger when any single machine attached to the DC is turned on
    • Need to get switches that will work with machines that have a variety of power sources (110/120V and 220/240V, Single Phase and Three Phase)
      • I believe all of the DCs are 110v/120v single phase.
      • SawStop 3 is ??? 3 phase
      • The sanders are both 110v/120v single phase
      • One band-saw is 110v/120v single phase, the other is ??? three phase (I think).
      • Small Joiner us 110/120v single phase (I think) and Planar is presumably ??? three phase
      • Large Joiner is ????
      • Router Table is 110v/120v single phase
      • Panel saw is ???
    • Price-point appears to be 40$ for simplest (what the Miter Saw currently has) up to 100$.
  • We should get automatic blast gates for systems attached to multiple machines
    • Machine Sets
      • Band-saws
      • Sanders
      • Small Joiner and Planar
    • Price-point is 100-200$ each. Some of these work as automatic DC switches as well.
  • We need an easier way to tell if the Dust Collection Drums are full
    • Ideas
      • Sliding panel in top of drum
      • Window in top or side of drum
      • Dip Stick of some sort
      • Alarm/sensors that actually work and cut off power to attached machine(s) if they trip (that is, the power tool as well as the DC will not turn on if full)
    • Research into what works in the real world
  • We could consider a system that cut off attached machines when Dust Collection bags are too full
    • Best way I can think of is to test by weight, but that's unreliable and won't work when system is running
    • Other ideas?
  • Some way to prevent users from unplugging dust collectors (mainly the DC for the sanders, but it might apply to others).
  • Better DC set-ups
    • Band-Saws
      • Get the spare DC into working state
      • Someone should determine what its actual state is
    • Miter Saw
      • Make Dust Hood
      • Search old email for plans that Woody linked to
    • Lathes
      • Tried minimal ShopVac attachment system for spindle work from Rockler; better than nothing but far from good
      • Designed general-purpose, permanent install PVC system
        • Design Description
          • Rigid 2" PVC pipes for piping
          • Attaches to Shopvac
          • Uses 2" to 4" PVC adapters (conical) for inlets
          • 4 Inlets: (1) behind lathe near head stock; (2) behind lathe, a foot towards tail stock from (1); (3) In front of lathe, ~6 inches from head stock, (4) under lathe bed by head stock
        • Price parts
          • 8 feet 2" PVC
          • 1 2" PVC Double Wye -- (ea @ 4.25$ Home Depot)
          • 1 2" PVC Wye -- (ea @ 2.28$ Home Depot)
          • 4 2" to 4" adapters -- (ea @ 6.75$ Lowes)
          • 3 2" Long Turn 90 deg elbows -- (ea @ 2.73$ Home Depot)
          • 4 2" 45 def elbows -- (ea @ 1.48$ Home Depot)
          • Adapter to ShopVac tubing


        • Need permission from Wood Board to install (presumably)

Shop Inventory

  • Do a full shop inventory (of Durable & semi-durable items)
    • Items to inventory
      • Hand tools
        • Bits
          • Router Bits
          • Drill Bits (in their various flavors)
          • Dremel Bits
        • Drivers
          • Screw
          • Socket
          • Drill
        • Wrenches
        • Pliers
        • Planes and scrappers
        • Hammers and Mallets
        • Saws
          • Saw Blades
        • Straight Edges, Squares, and other Measuring Devices
        • Files and Rasps
        • Clamps
        • Chisels and Gouges (Hand)
        • Chisels and Gouges (Lathe)
        • Other Lathe Tools
        • Marking Tools
      • Small Power Tools
        • Sanders
        • Saws
        • Drills
        • Routers
        • Batteries and Chargers
      • Accessories for large power tools
        • Blades (by machine type)
        • Belts
        • Carbides for Planar/Joiners
        • SawStop Breaks
        • Hand Guards/Push Sticks/etc.
        • Other semi-durables?
      • Jigs
        • Router
        • Table Saws
        • Others?
      • Out-feed/In-feed supports
      • Other random items
        • Ballast for Lathes
        • Shopvac/Dust Collection adapters
      • Tools for Tools
        • Sharpening Devices
        • Grinders
        • sharpening jigs
      • Shop-Specific Safety Items
        • Face Masks
        • Anything else?
      • Anything else I've forgotten
    • Determine what tools are excessive, not used, at their end of life, or otherwise unnecessary
      • Get Ride Of These Things
      • If No-one knows what something is, it probably can be ditched
    • Determine what tools are lacking or need to be replaced
      • Be Comprehensive
        • Some items need multiple instances (Common drill bits, hammers)
        • Some items tend towards being consumed (Scroll saw blades, small diameter drill bits)
      • Determine tool priority and importance
      • Find/replace high priority items
        • Prefer sets over haphazard collections
        • Prefer Donations over new purchases
        • Prefer Quality over not
    • Regularly (semi-annually?) repeat inventory.
  • Determine what consumables the wood shop should have
    • Determine which of these A^2 Should Provider
    • Determine which need to be donated
    • Determine which need to be self-provided
    • Post who is responsible for what in the shop
    • Source items as appropriate

Shop Organization

  • Install Cleats on all walls
    • Cleats need to be strong enough to hold tools
    • Cleats need to be at heights and locations that make them accessible to all shop users (Tall/Short, weakened grips, wheelchair users, any other access restrictions)
      • Check ADA/similar specifications for ideas
      • Create a list/Let users list themselves as people who should be consulted about accessibiliy issues
    • Cleats need to be prominent enough that we can use them for general shop signagge
  • Move existing hanging tools to be on cleats
    • Machine Cabinet (by SS3)
    • Lathe tools
    • Brooms/dustpans
    • other pegboards
    • Table Saw sleds
  • Determine which items should be in plain sight rather than in a drawer
    • Create or adapt hanging storage for these items
      • Clearly label what each spot is for
      • Clearly label what each storage unit is for
      • Maim anyone who ignores these signs.
  • Determine better storage mechanisms for fasteners
    • Mechanism that will encourage maintaining relative organization
    • Label, label, label
  • Brainstorm ideas to get the Multicam/Shopbot DC out of the woodshop
    • Reasons
      • We could use the space
      • The machine is, at best, a noise hazard
      • Put of Sight. Out of Mind problems
        • Not emptied as often as it should
        • Sometimes left on for hours after use
        • Noise baffling occasionally removed despite it being a physical danger to woodshop users to do so
    • Needs
      • Location where the DC could live instead
      • relocation for where-ever the DC ends up
    • Ideas
      • Move DC to where sheet storage is located (between Multicam and the welding shop)
        • Wood Shop takes over closet area
        • Wood Shop gives up corner where wood bin (currently) lives for sheet storage
      • Move DC to the hall corner by the Paint Shop currently occupied by non-flammable liquids
        • Would need to create some sound baffling
        • Would need to clean up the end of the hall, but that's already necessary
      • Move DC to above Paint Shop
        • Not sure if that's legal
        • Not sure if that's safe
        • Not sure what is up there so don't know how much would be displaced

Signage

  • Create hard to ignore signage
    • Bright Colors, flashing lights (as long as they aren't distracting), 3 foot tall letters something
    • Users are great at ignoring things. Try to work around this.
  • Per Machine Signage
    • (Long Term) Install Per-Machine RFID readers and limit the machines to those who have testing on record
    • (Short Term) Per Machine Sign-in Sheets/Clipboards
      • Include a list of users who have tested for each machine on the clipboard
      • Place clipboards in a location that makes it hard to turn the machine on without the user acknowledging it
    • Per Machine cleanup/usage instruction cards
      • Place in unavoidable per-machine location
      • make durable signs
      • Include relevant, per machine information (e.g. drill bit speeds, minimum length for planar)
  • Per Tool Storage Signage
    • Graphics and Text
    • Movable signs did not work -- too easy to remove, lose, or damage
    • Map of locations at front of shop
  • Per Shop Signage
    • TESTING
    • CLEAN UP AFTER YOURSELVES
    • Material Use Charts
      • Larger, and multiple
        • Material Use Chart for Wood
        • Material Use and Cleanup Requirements Chart for Non-Wood items
      • Include per-machine restrictions on per-machine clipboards
    • CLEAN UP DAMMIT
      • No Personal Storage
        • No, seriously.
          • Not until this evening, not until tomorrow.
            • I'm not kidding.
      • Drying glue-ups allowed for AT MOST 48 hours, if in an out of the way but safe location
    • Demark 'Danger Zones' (Behind SawStops, etc)
    • Demark storage locations for large items
      • Shop Carts
      • Infeed/Outfeed devices
      • Shop Vacs
    • Reminder to use the shop in a manner that does not prevent others from using the shop at the same time.
    • Reminder to clean up after yourself in a timely manner, even if you remain elsewhere in the shop
    • Reminder to clean up after yourself if you need to step out of the shop for more than 15-30 minutes
    • At least One Large, Working Clock
    • Time/Date/Location of Next Shop Board/Steering Committee/Planning/Whatever meeting
    • Reminder to be on the shop mailing list
    • Reminder to CLEAN UP FOR FRACKS SAKE
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