by Franz Fleckenstein

Created on: June 30, 2007

Step 1 ~ Plan:

The very first process in developing a fluent shop layout is to take raw dimensions of tools, such as workbenches and table saws, that you will move infrequently or not at all. Once you have the dimensions of these pieces, use graphing paper to cut out a representation of each tool in an easy ratio such as: 1 square (on the graphing paper) = 1 square foot. You may also find it helpful to determine the amount of shelving that you will be using so that space will also be allocated in your plan. With this you can cut out a model version of your shop and move each component around to determine the most suitable placement for each piece of equipment. Other important components in larger shops that are often missing in the planning phase are electrical outlets, compressed air and dust collection systems. If sanding is done frequently in your shop, dust collectors are worth every penny. For the model, you simply need to allocate floor space for the collector itself and place the tools that will use this system in close proximity to the collector (longer tubes are available but reduce the overall effectiveness of the system and increase the likelihood for clogging). For your electrical plans, simply install drop downs (self-recoiling extension cords) in the center of the shop and mount power hubs/boxes near the large components and workbench(s). The compressed air can either be installed as a drop-down or wall mount. The ceiling mount is preferred because you have little or no slack laying on the ground for someone to trip on. Wall mounts are a good alternative to pull-downs for shops with low ceilings.

Step 2 ~ Must Have Components:
Dust collection system
Power switches, hubs, extension spools (the more the merrier)
Adjustable and ample lighting (hand-held lights are sometimes nice too)
Remote Christmas light switch (allows you to shut off power to all devices to prevent children from injuring themselves)
Height adjustable shelving
Casters (locking wheel sets) for most every tool and working surface
Tackle boxes or specific hardware organizing bins (for screws, nails etc.)
Durable workbench with at least one vise
Sealed garage floor (great when working with finishes, adhesives and greased products)
Floor drains
And of course a decent stereo system (intercoms can be nice too)

Most all of the other essentials are dependent upon what the shop will be mostly used for (finishing, cutting and sanding, mechanical and automotive work, or general purpose).

Step 3 ~ Recommendations for General Layouts:

This is also very dependent on what type of shop you have but for the above listed essentials I would recommend putting non-movable tools against walls and avoid corners. For most tools, corners make it impossible to maneuver materials. Corner shelving, dust collection or air compressors are more suitable for these areas of the shop. Chop-saws and table-saws generally require a lot of working area so leave these plenty of room. Keep in mind where the materials will be traveling to determine the best possible location for each tool. For example, a chop-saw will almost always have the material running perpendicular to the blade. Placing the chop-saw against a long sided wall would be a desirable location. Finally, allow yourself enough room to maneuver not only your project but also yourself. Nothing is more difficult and dangerous than attempting aerobatics and gymnastics while operating powerful equipment.

Enjoy your new shop layout and always remember to measure twice and cut once!

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