Garage & Work van remodel - Router Forums
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post #1 of 21 (permalink) Old 11-06-2016, 09:33 AM Thread Starter
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Default Garage & Work van remodel

Several weeks ago someone here posted a link to Ron Paulk's Workbench 2. My brother told me about him several years ago, at the time I wasn't interested. This time my circumstances had changed as well as the workbench has been improved. So I decided to build one... or two. That was the start of a complete overhaul!
About 8 years ago when I moved into this house I built a 3'x6' table to inset my DW745 table saw. Some time later I saw a video of a woodworker with 12"x8'x4" torsion boxes on sawhorses with a 12"x48" top. The two torsion boxes were only 12" wide so they can slide around on the saw horses, one was melamine for glueing and painting on, the other was partical board, for cutting on. This setup worked well but left my shop rather crowded.
This version of the Paulk bench has an integrated router table and table saw support! So I decided to use my existing saw horses and built new torsion boxes, Paulk style, to replace the ones I had before. (sorry I can't remember who to give credit to for the idea I used on my original bench). By integrating the table saw support, I completely eliminated the table saw table, freeing up LOTS of sqft.
While researching the Workbench I watched a lot of Paulk's Youtube videos. This lead me to watching lots of other people's Youtube channels and to see his design for the Total Station, a 3'x6' version centered around a miter saw. I decided to build this too! I used it on Friday to trim a bathroom remodel I'm finishing and WOW WHAT A DIFFERENCE!!!! This is my first time doing trim without having the miter saw set on the ground or a 24" tall painter's platform.

I'll include current photos in this post, showing my progress so far. The next post will have photos of my previous setup and another post of my van's transformation.
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post #2 of 21 (permalink) Old 11-06-2016, 09:46 AM Thread Starter
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Here are some pictures of my setup before. Photos of the front and back of my table saw workbench. In the beginning the shopvac was inside the table, convenient but loud. Last year I moved the vac into the attic and ran PVC down to a filter box just inside the garage door then to a hose hanging from the middle of the ceiling. Now that I have the total station, I plan to move where the hose hangs from. The third pic you can see my old router table. It was in the way when not inuse and not very stable when I did use it, setting on the torsion boxes with the router hanging between them.
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post #3 of 21 (permalink) Old 11-06-2016, 09:55 AM Thread Starter
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I thought I took a picture of the total station all setup at the jobsite Friday but now I can't find it. That's the 3'x6' total station sticking out of the sawhorse under the Workbench in the first post. I built the Total Station to transport with me to job sites. This means that I need to rearrange my work van so it fits in there, along with all the other tools and supplies I carry. I didn't take a 'before' picture of my van, I'm sure I have some old ones somewhere but it was stocked FULL of stuff. The van came with steel shelving units along the inside of each wall. These were filled with tools and a few supplies. The middle space of the van 3' wide, 4' tall and 9' long was filled with Rubbermaid Brute bins, buckets, screw storage containers, tool tote, air compressor and when I bring them the table and miter saws. One huge problem with this design is that I needed to unload some of the truck at ever stop just to get the tools I needed. If I didn't put everything away every time (sometimes hard to do at 7pm when I just want to go home and eat) the van quickly turned into a mess!

Ok time to go to church so I'll continue later...
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post #4 of 21 (permalink) Old 11-06-2016, 02:51 PM
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The new workstation looks great, those feather boards look very impressive!
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post #5 of 21 (permalink) Old 11-06-2016, 10:31 PM
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Nice job.

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Rockhampton, Queensland, Australia


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ĎMembers are requested to add a first name in their profile as we are a very friendly bunch here'.
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post #6 of 21 (permalink) Old 11-07-2016, 11:18 AM Thread Starter
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Quote:
Originally Posted by Eugd View Post
The new workstation looks great, those feather boards look very impressive!
Thanks, I built a couple of 'barn door' style doors out of cedar 2"x6" - T&G together into a single slab. I needed some more feather boards to hold everything in tight. Once they were all shaped I had three stacks of boards so consistent that the tongue and grooves all lined up all the way up. As I finished shaping a board and laid it on the others I had to be sure not to lock it into the next stack.
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post #7 of 21 (permalink) Old 11-07-2016, 11:31 AM Thread Starter
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Last week and this weekend I spent some time building the first big drawer for the bed of the van, moving the power inverter, batteries, covering the wheel well and building the first tool drawer (drawer within a drawer). Before the batteries were vented with PVC hose but that was too bulky so I made a custom wood duct.
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post #8 of 21 (permalink) Old 12-31-2016, 04:09 PM Thread Starter
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Ohh, I found a 'before' picture of the van. I took this after buying the BB. Notice the steel shelving on either side that came with the van.
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Last edited by Everend; 12-31-2016 at 04:40 PM.
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post #9 of 21 (permalink) Old 12-31-2016, 04:12 PM Thread Starter
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I've made quite a bit of progress in the last two months. Lots more drawers, cubbies, shelves and stashes.
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post #10 of 21 (permalink) Old 12-31-2016, 04:15 PM
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Everand , I'm really liking the storage drawer in your van . The guys where I work aren't that capable , but this would work fantastic for them when they lower there tailgate and had access to all there parts .
The main drawer doesn't use drawer sliders?

I donít always insulate , but when I do .
Ok ,I never insulate
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