Makeshift Shop for Building Pram(s)

[Clinton B Chase]

All,

I am gearing up to build my first Nutshell Pram although I have sort of built one (a 4' version for my son to use as a cradle...just scaled the plans down by half). I am looking to make my basement into a makeshift shop for building a pram this winter. Could you folks furnish me with some ideas on how to set things up, a bench idea, what tools you think are a must (can't be stationary...too expensive) but various power tools that might make up for a lack of a band/table saw etc, dust collection, ventilation (I have very little), etc. It won't be a permanent shop; that is still a few years away. THANKS!

Cheers,
Clint
Portland, ME

[ssor]

First and foremost make sure the door to the outside is big enough. :D

[outofthenorm]

I'm assuming 2 things:
1 that you own a good basic toolkit of chisels, saws, a plane or two, a good hammer, screwdrivers, a drill and assorted measuring and marking devices.
2. that you didn't just finish measuring the door and saying the heck with the whole idea ;)

The fact is that you can build your pram entirely with hand tools, it just takes longer and creates more sweat. First, If you're gonna use handtools, the most important thing is that they are sharp. So first I'd think about a good sharpening system for chisels, spokeshaves, planes and handsaws. The forum archive has plenty of advice on that.
Second - I think there's two important considerations about a low-cost bench. It has to be long enough to lay out and work on your longest pieces, and it has to be sturdy enough to plane on. You can make a bench out of 2x material from the big box and a box of bolts and the best way to make it sturdy is to attach it to a wall. My first bench was in a basement "shop" and was crude as hell. But I lagged it into the concrete block wall and it never budged after that. A vise is ideal of course, but you can get by with nailed-on bench stops and dogs made from 3/4 inch dowel. Make sure there's enough overhang on the top to clamp to.
Third is clamps. You'll need plenty. You can make em yourself at pretty low cost with offcuts and 1/4-20 threaded rod and a selection of wingnuts and such. Greg Rossel's book Small Boat Building has plenty of ideas for that.
Finally there's the dust problem. If I was going to buy just one thing it would be a good air filtering system and a good shop vac (okay that's 2). Nothing seems to get a spouse as hopping mad as a layer of wood dust on everything in the house. If you have a forced air heating system that draws air from the basement, look out!
There's probably plenty more that others will add, but that's my 10 cents. Good luck on your build!

- Norm
(edited to correct spelling of the word vise. You already have enough vices, I'm sure)

[ 08-31-2005, 12:20 PM: Message edited by: outofthenorm ]

[Tom Robb]

Amen to what Norm said.
Wives seem genetically predisposed to equating sawdust with filth.
If you only use hand tools, sawdust will be minimal and more control-able.
Sharpen your edge tools early and often. It's like reefing sail. If you wonder if you ought, you ought.
Be sure you can get the boat out of the basement. If you can't, you'll NEVER hear the end of it. The story will follow you into the grave.
Boatbuilding is problem solving. The rest is practice.

[Andrew]

I'd recommend a low angle block plane, a must for plywood.

The one power tool I'd invest in is a saber saw. There are inexpensive models with a port to attach a shop vac to.

[pipefitter]

A Japanese Ryoba pull saw.Even the one with the disposeable blades. The most efficient handsaw you will ever use. Has a rip set on one side of the blade and a cross cut on the other.

[Clinton B Chase]

TX for thoughts. I have all the hand tools and I am looking to aquire a good jigsaw and a belt sander (which I'll use upside down as a "stationary"...I'd love to set up a router table but probably cannot afford a decent router yet). I'd like the router/table for trimming planks and other parts but if I don't get the router....How have other's cut out and trim planks accurately?

Norm mentioned a way of setting up a vise...can you clarify what you mean by "dogs"? Another mentioned the way to go is a jigsaw...will that enable me to cut out the miship frame and other pieces...I can't imagine doing these with out a router..

I would be interested in hearing what people have done in terms of layout of a little shop, sawhorses they've made, bench ideas, and how to deal with dust...I am looking into air filtration. I may make a bench out of 1/2-3/4 plywood on a 2 x 4 frame set on sawhorses that I may make. I have a set of sawhorses for the jig. I need a way to keep tools organized this time (got a lot of crap for that last project) and have to keep the basement clean this time!

I have enough door room to get the pram out.

Cheers,
Clint

[ 09-01-2005, 01:30 PM: Message edited by: Clinton B Chase ]

[bischoffboatworks]

I built my steambox (15 foot) to fix on a shelf behind my bench. I have one fixed bench with vises (not vices) attached. My planking bench is movable and has a shoulder vise at one end to hold the planks on edge for planing. The other end has an adjustable support to hold up the plank end. My basement is also my garage, so when I build 15 Whitehalls, I put them on a dolly that I can roll out onto the driveway to sand or paint/varnish. MY wife hates the smell of solvents kicking. Go figure. All the standing tools are on wheels so I can move things around as needed. The garage is only 16x12 so I have to move things around ALOT!

Good luck with your project.

[Clinton B Chase]

You folks have been helpful...would love a yes or no to these Q's if you could spare a few moments...

1) How wide/long to folks make their planking benches?...I will likely be building a few dinghies in the 8-12' range over the next few years...would a 2 x 8' bench do it?

2) Would a vise at one end and a clamp at the other end of the bench be enough to hold a plank for trimming/planing?

3) Do folks find a bench top belt sander pretty darn useful (or a power sander inverted) for fairing planks, softening edges, etc in their projects?

TX so much. I think I am almost coming to some conclusions for my makeshift shop!

[ 09-01-2005, 08:03 PM: Message edited by: Clinton B Chase ]

[outofthenorm]

Clint, bench dogs are the simplest way to keep the peice you're working on from moving on the bench. The link below is Lee Valley's expensive high tech version (and lovely things they are) but you can get exactly the same result using 3/4 inch dowel dropped into holes drilled at strategic spots on your bench top. My current 6 ft bench has about ten holes in it. Drill 3/4 inch holes with a spade bit. Wrap a turn or two of tape around the dowels and they fit nice and snug.The tape does the same job as the spring thingy on the lee valley set up.

In use, if you are planing a board, you can nail a scrapwood stop on one end of the bench to take up thrust along the length and place a dog or two on each side of a board, then use a couple of slim wedges to jam it in place. It's amazing how well it holds.
fancy bench dogs (http://www.leevalley.com/wood/page.aspx?c=1&p=31127&cat=1,41637,41645)

[outofthenorm]

Assuming you have the space, I'd make the bench about a foot longer than the longes plank you're likely to need.

I find my stationary belt sander pretty usefull, but only for shaping smaller pieces. I don't think it would help much in shaping planks. Could be wrong, though. :D - Norm

[Bill Perkins]

Clinton; I made my bench 32 in. wide and was glad I did . You're already thinking about 12 foot boats ;I would suggest a 16 ft. bench ,with a shelf behind it .A "ladder" frame is made from 2 16 ft. 2by 4 with short crosspieces 16 in. OC . This is nailed together on the floor . You want the ply top to overhang the supporting frame to facilitate clamping , as mentioned ; so for a 32 in. top , the cross pieces would be 29 in. long .Fasten this setup to the wall .I set mine 3 ft . off the floor , but I'm 6 ft. tall . Add legs in front .

The Bosh jigsaw is a superior tool that I think you 'd be glad to own .It will last your lifetime . For vises I use big hand screws ( the wooden things ).Laid flat on the bench and
secured to it with a c clamp .This will securely hold an inverted beltsander , and everything else as well .

[Clinton B Chase]

Was just looking at this beautiful bench at Rockler and learned about dogs then...

http://www.rockler.com/ecom7/product_details.cfm?&offerings_id=11090&SearchHandle=DADBDADJDADADDDGGFGBDCDFDJGEDIDGCNDIG G GEDCCNDEDADIDHCNGBGDDFDBCNDBGGGDGGGDDDGDDIGFGGGBDB DADADADBDADADADBDAHHGPHCGLCAGCGFGOGDGIDADADADEDADA DADADADADADBDFDADADA DBDADADADADADADADADADADADADBDADADADBDAHHGPHCGLCAGC GFGOGDGIDADADADBDB&filter=work%20bench

Your description helped....it would be an easy addition to my simple bench. OK...so maybe I will make my bench longer...couldn't I throw something underneath if a plank is too long for bench? Maybe I will use a 2 x 10' piece (I may not have enough space for a 10' long bench!)

Cheers,
Clint

[outofthenorm]

Hey Clint. If you liked that bench, you're gonna looove this one.
- Norm ;) bench porn (http://www.leevalley.com/wood/page.aspx?c=1&p=31152&cat=1,41637)

[ 09-01-2005, 08:54 PM: Message edited by: outofthenorm ]

[mwybo]

For what it's worth...
I am just completing a Pooduck Skiff in the garage. I asked myself many of these same questions. My solution was as follows:

Tools:
I bought two planes on Ebay and had some other hand tools around the house. Having more than one portable electric drill is a huge help so you don't have to constantly change bits and screw driver heads. I also bought a used Bosch sabre saw that I used for almost all sawing. I borrowed (or you can rent) a table saw to rip the strips for the midship frame and stems and to cut the plywood to manageable size pieces for the planks. I bought 6 good 12" clamps and a dozen cheaper ones and that worked fine.

Bench:
The garage is about 3 feet longer and 3 feet wider than the boat so there is no room for a bench. I made a set of sturdy sawhorses and used a sheet of plywood for a bench when drawing and cutting the planks and laminatingthe frame, then used the same sawhorses to support the building frame when planking and am now using them to support the boat for finishing. My other "bench" is an old workmate portable work table. I use my clamps to clamp the work to it. Also doubles as a vise.

Dust control:
I tried to do most of my dusty work outside and assembled the boat in the garage. This also gave me a lot more space in the garage. This was in winter in Montreal. You might have a bit more snow but probably not much colder. I have a cheap shop vac that I use to clean up after planing and light sanding.

Marriage control:
A few times I just called my wife's friends and asked them to ask my wife to go out so I could work on the kitchen table or the living room floor. This was never for anything dusty, mostly laminating when it was too cold in the garage.

I found that although it might take longer and that I had to redo a piece or two and that maybe the results are not museum quality I did build a pretty cool boat on my own which is what it is all about anyway. Like some of the others have said, the only absolutely essential piece of equipment is a door big enough to get it out of the house when you finish. You can improvise, borrow, and rent almost everything else.

Mike

[StevenBauer]

My offer still stands to come over and see my shop and various boat projects. I've also been known to be very helpful to fellow amateur boatbuilders. My friend Gary built a boat in my shop two winters ago. He'd come over on Saturday nights with a six-pack ( for after we were done with the power tools) and next thing you knew he had himself a little sailing pram. smile.gif
I also have the big shop tools that it sounds like you don't have. I've got a 16" bandsaw, table saw, planer, joiner. etc. So if you needed a bunch of strips cut to 3/4 x 3/4 you could just buy a 1 x 6 and rip it here then bring it back home. smile.gif
Another tip for anyone in the Portland area is to pop in to Mardens every few weeks - sometimes they have great deals on clamps. :D

Come on over!

Steven