Kirby's Shop Tour

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  • RodKirby
    Veteran Member
    • Dec 2002
    • 3136
    • Melbourne, Victoria, Australia.
    • Mao Shan TSC-10RAS

    Kirby's Shop Tour

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    This is actually my latest acquisition – it replaces my 17 year venerable Bench DP which sat on the stand now on the right of the DP. I was lucky I had enough room to do this – there weren’t any other options. I’m finding the flat top of the stand useful for working on both the DP and Router table.

    I always add drawers, if I can, when I’m locating any new tool – all that empty space (for me), at the bottom of the column… Most of my drawers are lined with corrugated cardboard (ridges across the drawer), helps to stop the contents moving around. I got the cardboard from my local "Pack & Send" store.

    The DP table was also used on the old DP and I discovered the only easy way to attach it was to drill/tap ¼”-20 holes into the front of the OEM table (no holes!), and use a connecting piece of plywood from the 1-1/4” MDF spacer under the table. The spacer is there to allow clearance for the handle which raises/lowers the table.
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    The large clamp is in the case because it began its life in my old garage where rust was a REAL problem. I’ve only needed it twice in 18 years so it’s easy to leave it there. Not obvious, but I had to move the case up 2” to allow the DP top to open (grrrr).
    The box on the left is my mini powerboard. And of course, WOOD’s excellent speed chart.
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    I have a tendency to “collect” drill bits
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    My Drill bit cabinet contains what you would expect – inch and metric bits, forstners, “spade” bits for glass/ceramics. The “stacked” forstners on the right have an 18mm and 30mm in front of the inch ones. My tall DP fence lives under the cabinet.
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    BTW If you notice any (small) holes in the MDF walls or pale “blank” spaces anywhere in the Shed, it’s because I seem to be constantly moving things. Also, if you see any ”empty” ¼” MDF pieces on the walls they are covering LARGE ugly holes.
    Coming up - Kirby’s Shed: 2. “Small” Router table.

    WARNING – you may notice some dust.

    Edit - Added floor plan - suggestion from Loring - thanks
    Last edited by Thom2; 04-28-2007, 07:56 PM.
    Downunder ... 1" = 25.4mm
  • RodKirby
    Veteran Member
    • Dec 2002
    • 3136
    • Melbourne, Victoria, Australia.
    • Mao Shan TSC-10RAS

    #2
    Kirby's Shop Tour

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    Small Router Table - WIP
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    I’ve decided to post these together – they are fundamentally the same.
    “S” = Small router/table, “L” = Large router/table. Paired Pics below show S on the left, L on the right.

    Router: S=Triton 2HP, L= Triton 3-1/4HP Both ½”, above table bit change.

    The tables are simply ¾” clear pine boxes with magnet caught fronts. Side entry Power-in socket, Router and Shopvac connection on/off together. Side entry Shopvac port.

    S table = 23” wide x 28”deep laminated MDF – 3/8” on 5/8”, no insert, router bolted directly on top MDF layer (hole cut in lower MDF layer to fit the base). Normally has a 1/8” roundover bit loaded.

    L table = 30” wide x 22” deep 1” MDF, laminate top and bottom, Phenolic plate + inserts (Woodhaven). Normally has a 1”dia. upcut spiral bit to handle all my rabbeting stuff.

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    Fences: Split UHMWPE with a slot for rear mounting and jig slots top and front.
    The micro-adjusts look complicated but really are not – indispensible IMHO. Both based on an idea from Pat Warner. Side clamps are from Woodhaven.

    L fence began its life on a smaller Woodhaven table. When I made the larger table, I had to extend the ¼” aluminum angle, so it looks rather messy – but it works!

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    Last edited by Thom2; 04-28-2007, 08:03 PM.
    Downunder ... 1" = 25.4mm

    Comment

    • RodKirby
      Veteran Member
      • Dec 2002
      • 3136
      • Melbourne, Victoria, Australia.
      • Mao Shan TSC-10RAS

      #3
      Kirby's Shop Tour

      As requested:

      This is my normal setup (Small Router Table fence), 1/4" Roundover bit.

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      This is an "exploded" view. Micro-adjust disconnected - can be removed to allow more space between the fence and the bit. The plywood "hook" over the fence front is simply to block the gap between the fence faces to aid DC. I also attached guides on each side of the base, to keep the fence from swinging during micro adjust.

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      Rear view: Micro-adjust now attached. Screws on the fence front (alongside the DC port), are only cosmetic - two on each side where I had a temporary DC port - yeah I know, but the holes looked ugly!

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      Example of the stops I regularly use (in pairs). The left one is mounted in the top slot and gives me an extendable stop. The right one is what I call a regular stop, mounted in the front slot.

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      BTW I have posted larger pics than I normally do - please let me know if this gives anyone a problem.
      Attached Files
      Downunder ... 1" = 25.4mm

      Comment

      • RodKirby
        Veteran Member
        • Dec 2002
        • 3136
        • Melbourne, Victoria, Australia.
        • Mao Shan TSC-10RAS

        #4
        Kirby's Shop Tour

        I wont include many comments now - I suspect there will be a few questions I'll pick as we go...

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        Here we go...

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        Forum member "Rainshadow" (Randy Atkinson), very kindly made the sign and sent it to me some years ago - been a while since I've seen a post from him

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        The beautiful frame Pappy presented to me in Houston in 2004 - Don, Pappy, Jim, Kirby, and Loring - thanks agin guys

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        Closer:

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        Attached Files
        Downunder ... 1" = 25.4mm

        Comment

        • RodKirby
          Veteran Member
          • Dec 2002
          • 3136
          • Melbourne, Victoria, Australia.
          • Mao Shan TSC-10RAS

          #5
          Kirby's Shop Tour

          These pics were a bit difficult to take - couldn't get back far enough.

          The jointer/thicknesser is a 10" Elektra-Beckum. A luxury item for me - I've only used it about 10 times in 12 years - but essential at the time.

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          Attached Files
          Downunder ... 1" = 25.4mm

          Comment

          • RodKirby
            Veteran Member
            • Dec 2002
            • 3136
            • Melbourne, Victoria, Australia.
            • Mao Shan TSC-10RAS

            #6
            Kirby's Shop Tour

            Stuff everywhere

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            The roller stand is from "Jigs and Fixtures” by Nick Engler, published by Rodale Press (He's my hero!)

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            Attached Files
            Downunder ... 1" = 25.4mm

            Comment

            • RodKirby
              Veteran Member
              • Dec 2002
              • 3136
              • Melbourne, Victoria, Australia.
              • Mao Shan TSC-10RAS

              #7
              Kirby's Shop Tour

              This completes the "around the walls" tour.

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              This is the "Shopvac" that follows me around - DP, router tables, BS.

              The Disk sander is a Festo that LOML bought me as a B'day gift - a gazillion years ago

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              Attached Files
              Downunder ... 1" = 25.4mm

              Comment

              • RodKirby
                Veteran Member
                • Dec 2002
                • 3136
                • Melbourne, Victoria, Australia.
                • Mao Shan TSC-10RAS

                #8
                Kirby's Shop Tour

                And now on to the stuff in the middle of the Shed...

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                The small bench is the only "wood" item I didn't make. At the time I moved from the old garage into the new Shed, this happened to come on sale for (about) US$100! I couldn't even buy the vises for that. I enclosed it all and added a shelf/door etc.

                It ended up being an ideal home for my CMS (only for cutting aluminum).

                BTW Wherever you see cabinets wired, the black receptacle is Power-in (from an extension lead). The white socket is to plug in the Shopvac. It gives me a single on/off switch to both the tool and the Shopvac.

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                This cabinet has 1/8" clear acrylic sides and (obviously), gets moved when I use the Bandsaw (blue Kreg fence).
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                Attached Files
                Downunder ... 1" = 25.4mm

                Comment

                • RodKirby
                  Veteran Member
                  • Dec 2002
                  • 3136
                  • Melbourne, Victoria, Australia.
                  • Mao Shan TSC-10RAS

                  #9
                  Kirby's Shop Tour

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                  Where it all comes together:

                  The Ryobi one on the left was on sale at our last WW Show - about US$30 Didn't need it but couldn't pass it up
                  My base (needed to be moveable), and top (don't like bare metal surfaces -other than the Table saw).

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                  The one on the right is from ShopNotes #30. VERY useful - the height adjustment makes it very versatile - has even been used for Quilting activities - at reasonable rental rates of course Worth the 4 days it took to build. 95% 3/4" MDF - so there!

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                  I made the top for this because it doesn't get much use - but great when needed! An Oz badged JET I think (?). The blue donut is my version of a DC adapter (MDF of course! laminated 2 x 3/4").

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                  Attached Files
                  Downunder ... 1" = 25.4mm

                  Comment

                  • RodKirby
                    Veteran Member
                    • Dec 2002
                    • 3136
                    • Melbourne, Victoria, Australia.
                    • Mao Shan TSC-10RAS

                    #10
                    Kirby's Shop Tour

                    The heart of the Shed...

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                    BEWARE - you are now entering the Darkside

                    Explanation: Back in August 2005, I was feeling uncomfortable that my trusty BT3000 would be a REAL problem if I had any motor issues - parts etc. no longer available in Oz (240V 50Hz). The BT3100 had just been relaeased in Oz and I got a chance to see it at a WW show. Unfortunately (?) it was displayed alongside what you see below. They were both the "same" price No contest - the BT3100 looked like a toy alongside this. The kicker was the SMT

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                    This "Shopvac" is dedicated to the saw. NOTE: The mobile offcut "cart" does not support anything - it just slides under the saw table.

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                    Here are some pics of it all coming together:

                    Base in progress. Saw attached to the OEM base for "lifting up".
                    I had 2 hefty friends lift it over to the new base while I aligned it with the bolt holes (I actually got them right!).

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                    DC connection:

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                    Miscellaneous:

                    Front and rear rails:
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                    Love that Woodhaven Miter fence
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                    Sorry about the clutter in the pic on the right - just wanted to show you how I setup the overhead guard.
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                    Attached Files
                    Last edited by RodKirby; 12-06-2008, 04:27 PM.
                    Downunder ... 1" = 25.4mm

                    Comment

                    • RodKirby
                      Veteran Member
                      • Dec 2002
                      • 3136
                      • Melbourne, Victoria, Australia.
                      • Mao Shan TSC-10RAS

                      #11
                      Kirby's Shop Tour

                      Mainly for my Darkside friends:

                      This started out to be a "trial" sled. I wasn't sure what I wanted/needed on my new TS. After 18 months, it has done all I've needed, so it stays as is

                      I seem to cut a lot of "smaller" stuff, and I find it difficult to exactly align a pencil mark to the blade - can't get over the top to see.

                      With the sled, I just move it towards me and align to the saw kerf

                      Note travel stop.

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                      Guard is 1/4" Lexan

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                      Support for the longer stuff:

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                      Length stops - for either side of the blade

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                      Two UHMWPE runners - 1/4-20 grubscrews for alignment

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                      Last edited by RodKirby; 12-06-2008, 04:27 PM.
                      Downunder ... 1" = 25.4mm

                      Comment

                      • GrosBoB

                        #12
                        Kirby's Shop

                        Congratulations for your shop,the storage cabinets and the many jigs you've built. Eveything is fantastic, interesting and very instructional ! The shop is clear, neat and very attractive ! It looks professional and is for sure a place where it is joyful to work. Keep on the good work.

                        Comment

                        • worm2003
                          Handtools only
                          • Sep 2008
                          • 1

                          #13
                          Nice work Kirby. That is one great looking shop. As a jigs and fixture man myself I must say that you did a great job on everything. Would love to have more details and/or how to on some of thos jigs.

                          Comment

                          • Larrysch
                            Forum Newbie
                            • Dec 2008
                            • 20
                            • Idaho
                            • Ridgid

                            #14
                            Holly Cow - what a shop - that is really something to be proud of - and my kind of a shop - nice and clean. Very well done and you should pat yourself on the back for a job "Well done".
                            (PS - you need to contact Wood Magazine and put that in their "American's best shops" for 2009.)
                            Larry

                            "I do not remember my mistakes - my wife does that for me"

                            Comment

                            • dbhost
                              Slow and steady
                              • Apr 2008
                              • 9209
                              • League City, Texas
                              • Ryobi BT3100

                              #15
                              Originally posted by Larrysch
                              Holly Cow - what a shop - that is really something to be proud of - and my kind of a shop - nice and clean. Very well done and you should pat yourself on the back for a job "Well done".
                              (PS - you need to contact Wood Magazine and put that in their "American's best shops" for 2009.)
                              Larry, Rod Kirby is one of our good mates from down under. I don't think he'd qualify for best shops in America... He might want to submit to The Wood Whisperer Shop Of The Week...
                              Please like and subscribe to my YouTube channel. Please check out and subscribe to my Workshop Blog.

                              Comment

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