Beewee - Woodwork
Sawdust from woodworking builds up and floats in the atmosphere - as part of the workshop design I created a "dust extraction" system that collects dust and other debris and deposits it in a bin for disposal.
The text (with more photographs) is also published as a .pdf document
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Small workshop dust extraction
My workshop is a single garage that also houses the CH boiler and HW tank as well as a cycle maintenance bench/tool-board and storage of 3 bicycles.
The simple and effective system was created from 40mm waste pipe and push fittings connected to a Henry vacuum cleaner, with home-made blast gates and 38mm flexible pond hose - with various connectors.
The waste pipe run is attached to the wall with plastic pipe clips about 40cm above the bench-top level, parallel to the electrical conduit run and power sockets. Waste pipe T-connectors are positioned at appropriate points on the pipe run with blast-gates - made from polycarbonate sheet and glued to the T connectors. For stability the T-connectors are fixed to the waste pipe with a small self-tapping screw.
The duct pipe connects with a flexible pond hose to a cyclone fixed to an approx 40 cm cube bin made from OSB, with all the joints on the inside caulked and a cased lid, with an all-round seal of draught excluder rubber, held closed with over-centre clamps. (I did experiment with a plastic drum but the suction caused it to collapse)
The cyclone is connected, with the same pond hose, to the Henry vacuum cleaner which, for convenience is connected to a remote control plug/socket with a fob to activate it.
Each of my machines has a hose connected to it (the ports all vary in size!) and either remain connected to the extraction system semi-permanently or are connected when the machine is in use - e.g. the mitre, track and band saws are connected all the time - the table saw is on wheels, stored under the bench with the router table and they are only connected when in use. A few hand machines (router, jigsaw, circular saw, sander) have dust-ports that can be connected to the system with a hose when in use.
I also have a separate hose with the Henry’s furniture crevice tool attached to it for cleaning up benches, machines etc. - it plugs into one of the blast gates (Easier and quicker than disconnecting the Henry’s hose from the system)
The dust separation is excellent with very little getting past the cyclone to the Henry’s bag - using the planer/thicknesser machine isn’t so successful as the waste is significantly larger. The only issue is remembering to open the appropriate blast gate and switch on the suction before using each tool!
There is also have a Record AC400 air-cleaner/filter attached to the ceiling that significantly reduces the dust in the atmosphere not captured by the extraction system.
The diagram illustrates the principles of the dust extraction system - the inlets/blast gates at the bottom and the fan (vacuum cleaner) pulling the air through the ducting into the cyclone which rotates the sawdust particles to drop into the collecting bin below.
A schedule of the tools - as an aide-memoire (which frightened me when I compiled it!) - amended as new tools are acquired/disposed of.
Bench Machines
Mitre saw (bevel)
Mitre saw (sliding, compound/bevel)
Bandsaw (Record 10" - new May 2024, replaced smaller Axminster machine)
Scroll saw
Planer/thicknesser
Drill press
Router table (built-in router)
Disc/belt sander
Bobbin sander
Grinding wheel machine
Polishing wheel machine
CNC machine with router (option to add laser cutter)
Record engineer's vice
Record woodworking vice
Hand power tools
Corded:
Drill (2 - Bosch & JCB)
Drill SDS (Bauker)
Palm router (Katsu)
Power-file
Biscuit jointer
Angle grinder
Dremel mini-multi-tool
Track saw
Circular saw
Hot melt glue gun
Heat gun
Sanding (2 - half-sheet & detail)
Belt sander
Soldering gun
Cordless:
Common battery platform (Einhell) cordless:
Impact wrench/screwdriver
Combination drill
Router
Angle grinder
Random Orbital Sander
Screwdriver
Circular saw
Oscillating multi-tool
Jig-saw
Plane
Hot glue gun
Reciprocating/sabre saw
Work lamp/torch
Vacuum cleaner
Dust/garden blower
Tiller/cultivator
Hedge trimmer
Drill (2 - one in screwdriver mode)
Nail gun
Engraving pen
Hand tools
Numerous, too much to list in detail! - pretty much what you would expect : saws (tenon, cross-cut, coping, hack, Japanese/flushcut), chisels, screwdrivers, hammers, mallets, planes, pincers etc, etc.
Pallet breaker/crowbar
Hand mitre saw/jig frame
Electric branding iron with brass brand logos
Plumbing related tools to cover most things
Clamps, guide rails, jigs & benches
Locking clamp straight-edge rails (2 off UJK/Axminster)
Trigger clamps (6 off 600mm, 6 off 400mm, 10 off 150mm, 10 off 60mm)
MFT clamps - (2 off horizontal, 2 off vertical/track saw, 2 off hold-down)
MFT bench dogs
Sash clamps (4 off Axminster, 2 off Record)
Kreg adjustable pocket-hole jig
Trend fixed-clamp pocket-hole jig
Vertical drill depth guide attachment
Mitre cutting box
Drilling angle-jig
Folding trestles with portable bench top
Workmate
Step-up working platform
Step-ladder (2)
Extending ladder (triple)
Marking & measuring
Squares, spirit levels, laser level, rulers, micrometers, verniers, bevel, mortise gauge, tape measures, laser measurer, moisture meter, multi-meter etc
Garden/exterior
Lawn mower (battery)
Hedge trimmer - large (battery)
Pole-saw (long-reach chainsaw)
Chainsaw, 12" (corded)
Karcher pressure washer
Karcher car wash/shampoo kit
Shredder for green material
Scarifier
Fertiliser/grass treatment distributor
French polishing/re-finishing
Sanding system
Scrapers, mops, brushes etc
PPE/Dust Extraction/Painting/Cleaning
Ducting system around the workshop with hose connections to blast gates for all machines + a general cleaning hose, powered by a Record filter/dust extractor (with remote control)
Record "air scrubber" filter mounted on the ceiling (with remote control)
Respirator
Ear defenders
Goggles and spectacles
Knee pads
Henry vacuum cleaner
Clarke compressor + spray kit
Vax steam cleaner
Ultrasonic cleaning tank (shared with the bike workshop)
Bike workshop area
Park Professional Workstand
Comprehensive range of Park Tool and other brand specialist tools
Millions of wooden pallets are discarded after just one use - the timber used is obviously not of the finest quality but is nevertheless useful as material for all sorts of projects (although most of them are fairly "rustic")
Breaking down pallets, removing the nails and planing/surfacing what is often rough timber takes a little time but it's therapeutic, and mostly out in the fresh air.
YouTube has an enormous range of projects, I'm only just starting with a few of my Pallet Possibilities . . . .
Fruit and vegetable rack (for a friend) - the raw materials (pallet timber planed and cut size) - and the end result.
Party wine and glass carrier - ready for action at the socially-distanced al fresco drinks sessions with the neighbours
Prototype boot rack - quick solution to test the size and position vis-a-vis cupboard and back doors
- pending an improved design, the final version will probably have an additional shelf
Carrier for the drayman - our neighbour across the road - "John the drayman" - manages the street's beer syndicate with deliveries every Friday, the carrier will make his life a little easier - it takes two 4pt plastic bottles.
Tiki bar - - made for us and our group of immediate neighbours to share - for alfresco drinks, parties etc. Made from a timber bedframe and pallet timber.
. . . projects to start/complete . . .
Squirrel feeder box - if only to stop them eating the bird food and plants in the garden
<<PIC>>
Garden furniture - planned to be built from both pallet timber and softwood decking (to be ready for Spring 2021)
The bench with side tables was at one of the bed and breakfasts we stayed at in New Zealand - the plan is to make a similar bench with side tables and a couple of single chairs to match.
<<PIC>>
. . . . . and of course, the joke about pallets and their possibilities:
"Here's a pallet I made out of an old coffee table"
Having originally created a workshop in two-thirds of a single-garage, the plan when we moved house was to have a double-garage - sadly this was not to be . . . we found the ideal house (February 2020) about a mile across town from where we lived but with just a single-garage 
The upside was that the garage was accessed directly from the utility room and housed the boiler/hot water system, which provides a very small amount of warmth.
With careful planning and utilisation of the benches, cupboards, racking etc from the previous workshop as well as building a new MFT* bench and incorporating the mitre saw I have a "compact and bijou" place to make and mend things - not forgetting the bike fettling area and hanging storage for three of my bicycles.
A number of the woodworking machines, and the bicycle workstand, are on wheels so they can moved from their storage/parked positions to be used.
Dust from woodworking is an issue so there is a ducting system around the workshop with hoses that connect to various machines and tools with blast-gates - all powered by a Henry vacuum cleaner pulling the air through a cyclone which diverts the dust and wood-shavings into a collection bin. There is also a ceiling mounted air-filter machine that removes much of the dust in the atmosphere. The Henry and air filter are both switched with remote controls.
There are some photographs of the previous and current bicycle workshops in the Bicycles/Workshop section of this website.
Update November2020 - the workshop ceiling has now been insulated and plasterboarded - together with the new insulated and draught-proof garage doors it will, hopefully, be a bit warmer to work in for the winter.
Woodworking area with tool storage and 3 machines (planer/thicknesser, scroll saw, table saw) mounted on trucks stored under a bench
Drill press with home-made table & fence Router table, home-made with router attached
The heart of the dust extraction and filter system - cyclone, sawdust bin, Henry - and the ceiling mounted filter (with remote switch fobs)
The orange-coloured hose connectors and adapters to connect to the machines were made by my brother using a 3D printing machine.
* MFT = Multi Function Table . . . a workbench that has lots of holes into which various clamps and guides fit for wood-working.
Various projects - for our own house/use unless otherwise stated
This section is becoming rather lengthy! - it's worth scrolling down for the content, I will probably split it into smaller segments in due course
Kitchen/dining table - made from birch plywood, exposed edges, with chrome hairpin legs and finished with a natural/clear oil.
Single drawer console table - made from birch plywood, exposed edges, with chrome hairpin legs and the same finish as the kitchen/dining table
Pantry shelving - fitted, making use of what was an empty cupboard - made from 18mm plywood, with inset shelves for strength - finished with a matt varnish/seal.
Pan drawers - utilising the space in a narrow kitchen unit (the awful granite is scheduled for replacement!)
Built-in shelving - to fit dead space having re-sited the fridge-freezer. Made from 18mm MR MDF, with adjustable shelves.
Domestic cleaning cart - made from plywood and wheel units recycled from an Ikea office cabinet.
There is a sloping understair cupboard and the cart was a solution for convenient storage of the vacuum cleaner and cleaning materials.
Fitness equipment storage box, on wheels - for a customer - the box and loaded (it rolls under a table to park it)
Repairs to a dining chair - for a customer
The chair frame joints had become loose - it was taken to pieces, the old glue cleaned off and then glued back together, with sash cramps to hold it in position while it dried.
Poppy display case - a ceramic poppy from the WWI Commemoration event at The Tower of London in 2014 - Blood Swept Lands and Seas of Red
Silhouette of a soldier - a Remembrance theme
I made this from some scraps of plywood in part to learn to use my newly-acquired scroll-saw and to create an appropriate decoration to have in the house for the few days prior to 11 November each year alongside the poppy. The photograph with the mug is to give an idea of the scale.
Display cases for model cars (two made for my brother) - the models are 1/8 scale (large!) the case is 70cm long
Work in progress - with all the component parts routed to receive the perspex panels - next stage is to stain and varnish before cutting mitred corners and assembly with a solid plinth.
The darker pieces of timber are for another poppy display case, also for my brother.
The case (one of two the same) finished - just needs the "floor" painting which is subject to seeing the case with what suits the car models in situ - one is a 1930 Bugatti, the other is a 1950s Citroen Light 15 (Traction Avant). My brother has full-size 1954 Citroen Light 15 on the road.
Two small engraved brass plaques to mount inside the cases
.. . . and the end results
Christmas decorations - snowmen and baubles, bears, a star and Father Christmas - in situ for 2020's festive (?) season . . . plywood cut-outs made on the scrollsaw and bandsaw.
Invitations - Two of our grand-children wanted an "experience" as a Christmas present - they are keen to go to the British Motor Museum so I made a couple of cut-out vehicles with the invitation text so they had something to open on Christmas Day.
Nativity cut out - a gift for a friend
Poppy display case - another one - for my brother. Ready to mount the Certificate of Authenticity and the ceramic poppy.
Tiki Bar - made for us and our group of immediate neighbours to share - for alfresco drinks, parties etc. Made from a timber bedframe and pallet timber
Squirrel feeder box - it took the little chaps a while to grasp how to open the lid and get at the nuts. Inspecting the box and then taking a nut (they now also climb inside the box!)
Under-sink slide-out trays - just making it easier to get to all those bottles stored in the cupboards (note the new black granite worktops)
Easter 2021 - in keeping with the season some more cut-outs on the front fence
Patio wall cladding - vertical battens and Thermowood (baked softwood, should outlast cedar) horizontal slats with recessed low-voltage lights, time-controlled by a Hive plug/socket.
Custom-size featheredge board garden gate/door - for a customer
The gate is to fit a narrow sideway where the fence and the neighbour's plot is at a higher level - gate is 225 x 65cm. Constructed from treated timber - framed, ledged and braced.
Above - prior to installation - the two "horns" at the bottom are to facilitate the fitting of the hinge pins to the house wall - when the door is hung, they will be sawn off.
Below - installed, showing the height difference
Up-cycling an IKEA bistro table - with a new top using offcuts of the cladding timber. Chairs before (green) and after painting and fitting new seat slats made from offcuts of the wall-cladding timber. Ready for alfresco breakfasts and morning coffee.
Garden fence and bin-store gate - work in progress, about 800 metres of the timber to install!
. . . and completed
Shelf units to display plants/fruit/vegetables outside shops - for a customer
Two versions, one painted with wheels and one unpainted without wheels (I prefer the unpainted look).
Made from rough-sawn timber using basic techniques for the "rustic, artisan" effect.
The initial "back of an envelope" design - and the finished products
Refurbish a "pavement find" kitchen stool - for the Tiki Bar
Varnish stripped off, joints stabilised, wax polished & seat-pad re-upholstered with new wadding and fabric.
Bar-stool - my personal "executive model" 
Made from scratch using recycled and left-over materials. The stool doubles up for use with the Tiki Bar and also in my workshop when I want to have a sit down.
A second, matching stool has been made, with both stools in action in a neighbour's garden (the laptop on the left is to watch the football (June 2021), and note the 18 pint beer box on the right!)
Another mobile shelf units to display fruit & vegetables outside one of our local shops - for a customer
Picture to follow . . .
More projects to follow . . . .
The list/work-in-progress:
Transport box for a Nespresso machine to take when we visit offspring that don't appreciate coffee.
Storage box to house/protect my mini-CNC routing machine
Stand/storage to house all the coffee, measures, jugs etc. beside our coffee machine
Further under-sink pull-out storage trays for the utility room
A revised version of the home-made router table
Something to use a piece of black granite that was the cut-out for the sink (possibly a small table using some beech timber recycled from a bed frame)
... and in the garden:
Some sort of timber structure for the area at the TRH corner - perhaps a brise soleil ?
The combined bench/table featured in the Pallet Possibilities section
... and for customers (the "order pipeline") - some from the Pallet Possibilities section
About 6 of the wine bottle/glass carriers
2 fruit and vegetable racks
A pair of bedside cabinets in the exposed-edge Birch plywood style, single drawer and open shelf.
