My New Shop: The Floor Plan

[LarryG]

Many of you know that back in March, I lost the use of the rented two-car garage that housed my shop. After packing up my tools and stashing them in a mini-warehouse just down the road from my house, I immediately began designing a new, dedicated shop building to be erected on my own property. This was actually my eventual goal all along; losing the rented garage merely accelerated the schedule by a few years.

The first step was to find out if the project was within financial reach. I reckoned that I needed at least a third more floor space than the 528SF of the rented garage, so I sketched up a plan for a 22'x32' building and got a preliminary quote from a contractor. His bid for the unfinished shell was low enough that I decided I could afford to make the building a bit bigger, if necessary, and so I cranked up the CAD software to see whether my tools would fit into the 704SF layout.

And it's a good thing I did. It quickly became apparent that I would need more like 50% more space than I'd had before; and the more I contemplated what I really wanted in what might well be the only shop I'll ever build, and the more I thought about the tools I plan to buy in future, the more square footage I added.

I wanted more than just raw space, however. From the outset, I wanted a separate room for assembly and finishing that would be small enough to economically heat and cool year-round. As the design evolved, the finishing function was split off into a separate room that could double as a storage room. I also wanted a small office, if possible; but at this point the building already measured 26'x32' -- the same length as it was originally, but now four feet wider -- and I was trying desperately to hold it to those dimensions, even if it meant omitting the office. But there were still some clearance problems out in the Machine Room that could only be solved by making the building longer. Since this would also allow the inclusion of a small office, I bit the proverbial bullet and increased the building's length to 36 feet, bringing the total enclosed space to 936SF. Suddenly everything fell neatly into place; virtually all the spatial problems disappeared. Finally, six months after starting work on the design, I arrived at this result (click for larger image):



The plan should be mostly self-explanatory, but there are a few things that may be worth a few words:

1. Ingress and egress for all purposes will be through the double doors at right. The single door at left will be only for emergency exit and ventilation.

2. Although the router table appears to interfere with traffic flow in and out of the shop, there is a 36" aisle between it and the cabinet saw's outfeed table, and it can be rolled out of the way when materials are being brought in or a large finished project is going out. Same deal for the diagonally-oriented work table ... it's on wheels.

3. Sheet goods store on a cart that parks in the Finishing/Storage Room. The cart can be rolled out onto the porch, which doubles as a loading dock, when a new load of plywood arrives. It will also be moved out into the Machine Room whenever a finishing operation is actively underway.

4. If the Machine Room isn't heated or cooled, the dust collector (or future cyclone) could be moved out onto the porch, freeing up some floor space for something else. I've shown it inside as a worst-case scenario, just in case I do want to condition the entire shop.

5. The building will be built on piers and will have a wood floor, both for comfort and so dust collection and electrical can go underneath.

6. Ceiling height will be nine feet, in all spaces.

7. The porch is noted as a future addition, to reduce the initial cost, but I really need it right away, so its construction will be deferred only as a last resort. I've not yet gotten an updated bid for this larger building, but I *think* I can get it built within my budget for the project.

Last but certainly not least, I would like to thank forum members Tom Miller and JR for their assistance in the development of this plan. Tom in particular worked tirelessly to offer ideas, feedback, and advice, and talked me out of doing some things that I now realize would not have worked nearly as well as I first thought.

So ... y'all look it over, tell me what you think, make suggestions, tear it apart. Thanks!

[JR]

Great looking design, Larry. It's very well thought out. I am deadly envious over the amount of space being contemplated!

I'm still a bit hung up on the office door located in the assembly room - I've been accused of being obsessive - but it's the only less-than-optimal flow problem that is obvious to my eye.

Good luck with the project!

JR

[Mr__Bill]

I'm still a bit hung up on the office door located in the assembly room - I've been accused of being obsessive - but it's the only less-than-optimal flow problem that is obvious to my eye.

To me it makes good sense. The assembly room should be relatively clean, this should help to keep the office clean. I will be interesting to see the layout a year after you have moved in to the shop.

I am wondering, where is the commode and refrigerator?


Bill,

[crokett]

I dunno. I guess it depends on how often he is going to go the shop just to go to his office. I suppose you could move the door to open directly onto the shop but then where would the DP and the tool chest go? I like the door where it is too - it will help keep the office clean and dust free.

[LarryG]

Dust control is indeed one reason the office opens onto the assembly room. I'm going to try to not use power tools in the assembly room, or at least restrict their use as much as possible. The other reason is that I want the office to be heated and cooled. There will be insulation in the walls around the assembly room, and the office will be included within this envelope. My intent is to keep the office door closed except when I'm actually in there; being a small room, it should come up or down to a comfortable temperature pretty quickly simply by opening the door.

What I DON'T like about the office's door location is that I can't see a visitor coming into the shop. I may sacrifice some of my fastener/hardware storage bins to make room for a small borrowed light that looks out onto the machine room. It wouldn't have to be very large: something about the size of a portlight for a boat would work. (In fact, if I could find a used portlight for cheap, that might be rather cool ...)

I have a larger library-slash-office in the house, so the shop office will be used strictly for woodworking-related stuff. I need shelf space for my books and magazines (I'm out of room in the house) and for a computer so I won't have to run to the house every time I need to look at a CAD drawing or SketchUp model.

I am wondering, where is the commode ...

Oh, right, I forgot ... that's the THIRD function of the porch/loading dock.

... and refrigerator?

Under the credenza-like back counter in the office.

[Mr__Bill]

What I DON'T like about the office's door location is that I can't see a visitor coming into the shop. I may sacrifice some of my fastener/hardware storage bins to make room for a small borrowed light that looks out onto the machine room. It wouldn't have to be very large: something about the size of a portlight for a boat would work. (In fact, if I could find a used portlight for cheap, that might be rather cool ...)

You could put in a web cam to monitor the front door, that way you could watch the shop from the house too. Better yet, a Tool Time type hostess to announce visitors to the shop.

[Hoover]

Better yet, a Tool Time type hostess to announce visitors to the shop.

Then nothing will get done, except maybe a divorce!!

[pelligrini]

Better yet, a Tool Time type hostess to announce visitors to the shop.

Gonna need a couch in the office for that accessory...

That plan is pretty well thought out. Not too much to add.

You might think about putting the HVAC under the window directly across from the double doors to the assembly room. You'd free up more of the wallspace between the windows and be able to direct conditioned air into the rest of shop when needed.

Do you spray a lot of finishes? You will want to protect your materials on the cart if you do spray in that room.

The only other thing that might be a problem sometimes is the placement and orientation of your workbench. It looks like there is less than 2' on the ends. I'm making due with even less, but I don't like it. If I've got the tail vise really open there's even less room. Your mobile assembly table will let you pull the bench away from the wall so you can work from all sides from time to time. It's not that big of a problem for me, I have to deal with tight spaces in my little shop/shed.

[Pappy]

I am also jealous. I have a 24x26 steel building that is still laying in the yard. Several financial setbacks have kept me from being able to pour the slab needed. I think I see a faint, distant light at the end of the tunnel (Or an oncoming train!). Maybe by next spring I will be where you are now.

Post pictures after the construction begins.

[LarryG]

HVAC Unit: I had it under that window, at one time, for just that reason. It offended my annoyingly overdeveloped symmetry bone. I moved it because I thought the more central location might benefit the office. I may yet move it back.

Protecting Materials While Spraying Finishes: That's why the sheet goods cart is a cart. So it can move to a protected location when necessary.

Workbench: There's right at two feet clear at each end ... 1'-11" to be precise, assuming the seven-foot-long bench is centered. A bit more clearance wouldn't hurt but that's approximately what I had in my previous shop, and it worked okay. I will probably cheat the bench placement slightly to the right (as you face the bench), to provide more room at the tail vise end.

Photos: Oh, definitely, assuming this thing actually flies (which I think it will). I've been piddling around with a SketchUp model and may post some views from it, too, if I ever get it finished.

[Ed62]

Wow, Larry! What a great setup!! It's easy to tell you've been keeping your brain busy.

Ed

[Tom Miller]

...Tom in particular worked tirelessly....

Well, if you ever needed proof that you can't trust what you read on the internet....

I think it's easier not to be too jealous when you have no ray of hope of doing something this cool yourself. Instead, it's been a lot of fun looking over designs, and problem-solving space issues (albeit on a much bigger scale than I have in my 225 sq ft!). Talk about livin' vicariously!

And now, to up the ante, I offer a PM2000 to the first person that points out a design aspect that Larry hasn't thought through three ways from Sunday.

Regards,
Tom
p.s. I reserve the right to define what a PM2000 is, just in case.

[LCHIEN]

Obviously a lot of thought went into that plan.
The only thing I don't really like about it and maybe its just me, is the office.
One its kind of claustrophobic 5 x 8 and 9 feet tall?.
Two, it seems like a waste of space and three it seems like its too disconnected from the shop. Isolation for an office is good if you are trying to keep yourself away from noise and distraction but since its a one man shop that seems an unlikely need. I would feel an office nook a need to be able to look up info on the web and designs on my computer. I would envision a shop office not being used for long periods of time for design work (I do that inside the house in the company of the family room so I can converse with the family). Rather for reference and quick calculations or changes.

How about this:
Move the desk under the bookshelf. The bookshelf could go the ceiling and still have almost 6 feet of shelves above the 28" desktop height and 12" working room with 9 foot ceilings. A small step-stool might be needed for reaching the top shelves but I would expect you to have a 4-step ladder handy in such a shop. Now you can do away with the doors (close off) to the assembly room and the back wall. The mechanics tool chests usually have wheels so you can move it arond as needed. Put your computer into a under-desk cabinet that vents to and from the assembly room so your main shop area dust won't clog up the computer works.
Some more juggling will ensue - the parts bins to the assembly room - probably better placed, anyway. The DP against the wall where the door from the office to assy room was, or maybe next to the grinder? DP should be mobile anyway - I find sometimes I have to drill a series of holes on long pieces requiring a lot of right and left clearance.
Anyway, your desk will now be able to be accessible from the main shop more quickly and I think it frees up some floor space (for the desk at least) or at the very least makes the shop look more open.

[chopnhack]

It looks great Larry, I can offer no advice but a hearty thank you as I am forever planning to design my garage and your layout provides alot of guidance. Thanks again!

[LarryG]

Loring, the office has been a real bear to get right (ain't that so, Tom?). There's a few things I've not yet explained that may alter your views -- or not. At the very least you'll understand how I came to this arrangement, even if you still don't agree with my thinking.

First: I understand your and JR's concerns about the office feeling disconnected from the machinery area. However, I regard (and this may be just me) the Hand Work/Assembly Room as the heart of this shop. That may be because it'll be a more serene environment than the Machine Room, and the office seems to mesh well with that. Or it may be because it is the only room that will be heated and cooled, to make it usable year-round. Having the office open onto the assembly room allows it to pick up some "free" conditioned air.

Second: the shop office will be my primary office for anything and everything pertaining to woodworking. I'll do some design work in the house, sure, but a lot of it will be done in the shop office since this is where my reference books and idea files will be kept. (When I said that I didn't want to have to run back to the house to check a CAD drawing or SketchUp model, I was actually thinking about referencing archived files, not the ones for the current project.) I'll be spending a LOT of time in this room.

Third: yep, at 5'x8' it is indeed a little small; but I've no problem with those dimensions. Small spaces don't bother me a bit. And while I did say that all spaces would have a 9' ceiling, I forgot to mention that I'm thinking I'll lower this one to 7' or so and use the remaining space above (about 20" net) for some kind of dead storage. Lastly, both the office doors and the doors entering the assembly room itself will have glass in them, specifically to make these two spaces feel more open, more connected to each other and to the rest of the shop.

Fourth: I want the office behind doors, to protect it from dust. That's a non-negotiable point, and has been from the beginning. In my previous shop the "office" was a four-foot section of a long countertop, on which I sat my laptop computer and stereo and some books and whatever else. I hated that arrangement. Even with good dust collection, things were always a mess. So, at minimum the desk would need to be in a closet some 42" deep (allowing room for the chair) and when you consider the space required for the closet doors to swing open, hardly any usable floor space would be gained.

Now ... with all that said, before I started writing this I made a copy of my floor plan and, in the interests of thoroughness and objectivity, tried to modify it per your suggestions. I can position the desk, by itself, in any of several locations and shift the surrounding stuff around and make it work. But when I try to create a deep closet to contain it (opening onto the assembly room, for heating/cooling purposes), things really don't work out any better than what I have now.

But with THAT said, I want to say that I genuinely appreciate the feedback that you and everyone else is offering. I started this thread because I'm seeking the thoughtful input of the members here; I want to tap into the collective's wisdom. If it seems like I'm dismissing any of these suggestions out of hand, without giving them due consideration -- that is absolutely NOT the case. As I said, this may well be the only shop I'll ever build from scratch in my life, and I want to get it as right as I can. So ideas and criticism are welcome, even if I ultimately don't pay them any mind.

Regarding your other points:

Tom (or was it JR?) has already questioned the location of the fastener/hardware bins. It's highly likely that I'll move some or all of these to the piece of wall above the HVAC unit. Actually, I think the ideal location for these bins might be the wall just outside the assembly room doors, where the mechanic's rollaway and drill press are. That would make them equally handy to the Machine Room and the Assembly Room. I've not found a better place for those other two items, though. But I'm still looking at it.

One of the benefits of my rented space was that it came complete with a floor-standing drill press. I'll now have to buy one, and I've not decided whether to get a floor model or a benchtop. I'm leaning toward the latter because (a) I've never come close to needing the full vertical capacity of even the average benchtop DP, let along a floor model; and (2) a benchtop can go on a rolling cabinet which will offer some additional storage space and be a lot more stable than a floor-model DP on a mobile base.