Installing a Woodshop Dust Collection System

As you may know, I recently moved to a new shop where I’m building furniture full time.  This gave me the opportunity to overhaul my old dust collection system.  Previously the system used a 2hp single stage collector with 4″ flex hose running to all my machines.  I was never happy with its performance and assumed it was the fault of the collector since my shop at the time was small and the runs were short.

The new system uses the same 2hp collector but the ducting is 6″ diameter HVAC metal ducting with 4″ diameter flex hose only at the tool.  This system performs so much better than my old set up.  I now blame the olds system poor performance solely on the flex hose.  

Check out the video below to see how I installed the new system and look below the video for links to the products I used in building it.

Items used in building the dust collection system:

Midwest Ducts 30 Gauge Galvanized Pipe – 6″ x 5′

4″ x 10′ Clear Flex Hose

Ideal-Air 750105 Adjustable 90 Degree Elbow, 6″

Speedi-Products SM-RDP 65 6-Inch by 5-Inch Round Galvanized Plain Reducer

Single Wall Galvanized Metal Duct Reducer 5″ to 4″ / 5″ x 4″

6″ x 6″ x 6″ Sheet Metal Duct Wye Branch HVAC

Nashua Aluminum Waterproofing Repair Foil Tape, 11 mil Thick, 10 m Length, 48 mm Width

Diversitech 710-001 Galvanized Duct Hanging Strap 1 x 100 Ft

POWERTEC 70108 4-Inch Blast Gate for Vacuum/Dust Collector

Woodstock W1023 5-Inch Hose Clamp

There are a few more pieces that i need to find again but this will get you started,

If you like what I do and are interested in helping out, consider supporting my work on Patreon.

Shop Update 1/18/2017

In this update we go for a quick tour of the new shop on the farm in PA. 

I’ve had a lot of help from some localish guys: Gib Clark, Mark Saunders and Tim Webster. Thanks so much guys. 

The new jointer is in and running, the tools are where I think they are going to go. It’s time to run ducting for my dust collector!  Check the video below. 

If you feel like helping to support what I do consider checking out my stuff on Patreon

Moving a 2,000 Pound Jointer

I recently purchased a L. Power & Co. 12″ jointer.  It is massive and made completely of cast iron.  

I got a great deal on the jointer but of course I had to move it from its current location to my new shop.  This presented some challenges.  Here is the video of the move.

To get the job done I enlisted the help of my Dad and a few friends, Gib Clark and Mark Saunders.  Gib is one of those guys who knows a lot about a lot of things and he was instrumental in getting this job done.  Mark was generous enough to let us use his truck to haul the jointer in the U-Haul trailer that I rented and my Dad was the extra muscle.

We stated moving the jointer by removing the 3 phase 5 horsepower motor and blade guard.  This just make the jointer a little easier to maneuver through the shop.  Then we slid the jointer on to a 2×12 and used a pry bar to get some short lengths of conduit pipe under the 2×12.  This allowed us to roll the jointer to the other end of the shop where the garage door was located.  

Once we had the jointer to the door we were fortunate enough to be able to use the owner’s Bobcat to lift the jointer out of the shop and onto the trailer that I rented.  

Gib brought some tow straps that we used to provide spots to lift the jointer from using the forks on the Bobcat.  Once we got the jointer off the ground, placing it in the trailer was a piece of cake.

From there is was only a 3 mile drive to my shop.  At my shop we unloaded the jointer using a chain fall that Gib attached to a beam on my ceiling with some steel rope.  We simply backed the trailer into my shop, and used the same tow straps to attach the jointer to the chain fall.  We then very easily lifted the jointer off of the trailer and drove the trailer out from under it.  

To get the jointer into its spot in my shop we lowered it on to the metal conduit pipes again and rolled it into place.

This could have been a much more difficult process and I really want to thank my Dad, Gib and Mark for all their help.  I never could have done it with out them.

 

If you like my work, consider supporting McCauley’s Design on Patreon

Inside Out Turned Ornament

For a long time I’ve wanted to turn a Christmas ornament for our tree.  Each year the holidays come and pass and I never have the time to make it happen.  This year was different.

I grabbed some walnut and mahogany I had laying around the shop and got to work.  This was my first attempt at doing an income out turning.  It’s not perfect but it is certainly acceptable for a first go.  If you’d like to see how I made it check out the video below.

2016 Woodworking Holiday Gift Guide Under $50

2016 Woodworking Holiday Gift Guide Under $50

Every year people always ask what sort of gifts I would like for the holidays.  Of course my mind immediately goes to woodworking, as does theirs.  But buying gifts for a woodworker can be intimidating.  We all have our own preferences and gifting something that falls within those preferences can be difficult.

This year, I’ve decided to put together a list of woodworking related gifts that can be purchased for the woodworker in your life.  Or that the woodworker in your life can point you to for a little help.  The majority of these gifts can be had for $50 or less!

 

    • Corner Chisel – This is a super handy tool for cleaning up the corners of hinge mortises.

 

    • Chisels – Even the most devote power tool woodworker needs a set of chisels!

    • WorkSharp WS3000 Sharpening System – While this one is more expensive then $50 the woodworking in your life will love how easily they can keep their tool edges sharp with it.

    • Kreg Pocket Hole Jig – Not everyone uses pocket holes all the time but they sure are handy and everyone has a use for them sometimes.

    • Kreg K5 Pocket Hole Jig – This jig does the same thing as the previous one but it’s faster and easier to use.

    • Pocket Hole Screws – If you are making pocket holes, you need the screws to go with them.

    • F Style Clamps – Not only do woodworkers need lots of clamps, they need several different types.

    • Leather Strop – If you are using chisels or plane irons in your shop you need one of these, along with the honing compound to keep those edges sharp.

    • Bench Cookies – Similar to the painter’s pyramid, these are great for keeping your work stationary while sanding or planing.

    • Bench Dogs – A must have accessory for any workbench with 3/4″ diameter dog holes.

    • Hold Fasts – Along with the bench dogs, if your woodworker uses a workbench these are a must have accessory! Be sure to buy two of them.

This is just a small list of things that any woodworker would love to get as a gift for the holidays or any other occasion.  I personally use many of these very same products or would love to have them in my shop.  Buy with confidence for the woodworker in your life this year!

All of the links above are affiliate links.  That means when you purchase something, anything, through a link I’ve provided I’ll receive a small kick back from Amazon at no extra cost to you.  Thanks for the support.

Streets of New York | a Jimmy DiResta Film

An episode or two or three ago the guys at the Making It Podcast suggested that someone out there in the world make a compilation video of every time that Jimmy DiResta said “streets of New York” in his video celebrating 600,000 youtube subscribers.

I waited a little while before making the video because I assumed that later the same day that the episode was released the video would exist.  It didn’t, so I made it.

If for some reason you haven’t already, be sure to check out Jimmy’s YouTube Channel.

Enjoy the video:

 

A New Handle…

We have a hairbrush and the handle broke off of it.  So instead of throwing it out I turned a new one for it from a walnut scrap.

This was a really easy and simple project and I debated about whether or not to film it at all.  However, it afforded me the opportunity to begin to get used to using my traditional turning tools instead of the carbide tools that I typically use.

If you’d like to see how I fixed the brush, check out the video below.

Building a Split-Top Roubo Workbench

Recently The Dusty Life Podcast hosted a workbench build off. I decided to build a split-top Roubo bench.

The bench measures 6′ long by 24″ wide and 34.75″ high. The top and base are made from SPF construction lumber. The leg vise chop, wagon vise and sliding deadman are mahogany and the planing stop is walnut. The bench has other walnut accents as well such as the vise handles and hubs. 

Having a real workbench in the shop is a real game changer. I can’t believe I waited so long to build one. Check the videos below to see the build process. 


Walnut Barn Door

Seems like sliding barn doors are all the rage these days.  Turns out I was recently commissioned to build one.  In my case, it was just the door.  The client took care of the hardware so I didn’t have to deal with that.

I built this one out of walnut lumber.  I absolutely love walnut.  The basic construction is frame and panel.  It came together really nicely and all in all its a pretty simple build.  If you like to see how I went about it check out the video below.

 

 

Reclaimed Bar Top with Epoxy Finish

I was recently commissioned to build a bar top from reclaimed 2×4 lumber that was pulled from the walls of a home that was being renovated.  The client wanted the bar top to be finished with bar top epoxy.  This is something I hadn’t had the opportunity to try before so I gladly accepted as I’m always looking to try something new.  Check out the build video below then keep reading  for information about the products I used and other specifics about the build.

The epoxy was definitely and experience.  I ended up pouring two gallons of epoxy on the top and a lot of it ended up dripping off the edges and onto my floor.  Of course I had drop clothes and other measures in place to catch all of the dripping epoxy.  While the mess was contained, it was hard for me to see all of that epoxy all over my shop.

Products used:

Festool 574447 XL DF 700 Domino Joiner Set

Festool 498899 Assorted Domino Beech Tenons and Cutters in T-Loc Systainer

Festool 561593 Carvex PS 420 EBQ Jigsaw

Grizzly G0715P Polar Bear Series Hybrid Table Saw with Riving Knife, 10-Inch

Jet JJP-10BTOS 10-Inch Bench-Top Jointer/Planer

Rockler 3-Piece Silicone Glue Brush Application Kit

Best Bar Top Epoxy

Minwax 70046 1 Quart Wood Finish Interior Wood Stain, Red Chestnut