Build a Shop: First Steps

The first stage of building any shop is planning. Before you break ground or purchase materials, take time to really think through your shop goals and requirements. This upfront strategizing will save you time, money and headaches down the road.

First, determine the primary purpose of your shop. Will this be a hobby space where you tinker on projects in your free time? Are you looking to start a woodworking business and need a professional-grade facility? Will you be doing only woodworking or also tackling metalwork, automotive or other projects? Knowing how you plan to use the shop will dictate many of your later decisions.

Next, consider your budget. Building a shop is a significant investment, so it's important to get a realistic sense of what you can afford. Make a list of must-have features, and then price out the building materials, tools and equipment you'll need. Don't forget to factor in any contractor costs if you won't be doing the construction yourself. Once you have a ballpark budget in mind, you can start refining your shop plans to fit within those constraints.

Location is another key consideration when building a shop. Many people choose to construct their shop on their own property, either attached to their home or as a separate outbuilding. This is convenient and can save on costs, but be sure to check your local zoning laws and permit requirements before you build. If a home shop isn't possible, you may need to look into renting or purchasing a commercial space for your needs.

Shop Size & Layout Considerations

Once you've nailed down your shop's purpose, budget and location, it's time to start thinking about layout and size. This is where the fun really begins, as you get to dream up your ideal workspace and all its details. But there are also practical matters to consider to ensure your shop will function well for your needs.

When determining your shop's size, think about:

• The types of projects you'll be working on (bigger projects require more space)

• The tools and equipment you'll be using (large machinery has significant space needs)

• Whether you want extra space for an office, bathroom, storage, etc.

• How many people will be working in the shop at once

• If you anticipate your space needs changing in the future

Once you've landed on a target shop size, it's helpful to map out your ideal layout. You can do this with simple graph paper and a pencil, or use an online floor plan tool for more precision. Some key layout considerations:

1. Workflow: Arrange your shop layout based on your typical workflow, with tools and equipment placed in the order you typically use them. This will save steps and increase efficiency.

2. Tool placement: Position stationary power tools like table saws and planers first, as these are the anchors of your shop. Arrange smaller tools and benches around the perimeter.

3. Safety: Ensure there is ample space around each power tool to avoid dangerous crowding. Keep flammable items away from heat sources.

4. Storage: Plan for plenty of storage for tools, materials, hardware and safety gear. A mix of open shelving, drawers and cabinets is ideal.

5. Flooring: Select shop flooring that's durable and easy to clean. Polished concrete, epoxy, rubber mats and wood are all good options. Avoid tile as it's slippery and prone to shattering if you drop a tool.

6. Exits: Don't forget to include adequate exits for safety purposes. A separate man door in addition to the main shop door is recommended.

Must-Have Shop Features

In addition to square footage and layout, several other features are essential to creating a functional, comfortable and safe workshop. Here are some key things to include as you build a shop:

Lighting

Good lighting is essential for any workspace, but especially one filled with dangerous power tools. You'll want a mix of ambient and task lighting to ensure you can see clearly for detail work. Some shop lighting tips:

• Install overhead lighting on a grid for even illumination. LED shop lights are energy-efficient and provide good color accuracy.

• Add task lights over workbenches and tools. Adjustable LED swing arm lamps work well.

• Include plenty of windows for natural light. Skylights are a great option if wall space is limited.

• Make sure your lighting is bright enough. Aim for 100 foot candles (1000 lux) for close work, 50-100 foot candles for general work areas.

Electrical

All those power tools need juice, so adequate shop electrical is a must. Work with an electrician to map out your needs, but in general aim for:

• Multiple 110V outlets spaced around the perimeter for small power tools

• 220V outlets for larger equipment like table saws and dust collectors

• At least one 20-amp circuit for the shop, but multiple 30-amp circuits are better

• Plenty of ceiling drops for powered equipment like air filters and lights

• GFCI protection anywhere near a sink or other water source

Ventilation

Wood dust and fumes can damage your health, so good ventilation is critical for any shop. There are two main elements to an effective system:

• Dust collection: A dust collector with ductwork to each major tool will capture the bulk of sawdust before it becomes airborne. Look for a cyclone or two-stage collector with a 1+ hp motor and filtration to 1 micron.

• Air filtration: An ambient air cleaner mounted on the shop ceiling will catch the finer dust particles that escape local collection. Choose a unit that cycles the full volume of shop air at least 6x/hour and has a MERV 13+ filter.

Heating & Cooling

No one wants to work in a freezing cold or sweltering hot shop, so plan for climate control from the start. Insulating the walls and ceiling is step one. Then, depending on your climate, you may want to include:

• A gas or electric heater for cold weather (make sure it's rated for wood shop use)

• An evaporative cooler or mini split AC for hot weather

• Ceiling fans to circulate heated or cooled air effectively

• Windows placed for cross ventilation

Plumbing

While not essential, adding plumbing to your shop can be a game changer for comfort and convenience. Consider including:

• A utility sink for washing up and cleaning tools

• A toilet for obvious reasons

• An eye wash station for safety in case of accidents

• Hose bibs for easy water access

Outfitting Your Shop for Comfort & Efficiency

Once the bones of your shop are in place, it's time to outfit the space for maximum comfort and efficiency. This is the fun part where you get to personalize the shop to your unique needs and preferences. Here are some ideas to consider as you build a shop:

Custom Workbenches

Every shop needs a sturdy surface for working, and custom building your own benches allows you to tailor them to your height, typical projects, and workflow. Some features to consider:

• Adjustable height for confort whether sitting or standing

• Built-in power outlets, lighting and ventilation

• Integrated storage for frequently used tools and hardware

• Durable work surfaces like butcher block or steel

• Casters for mobility if needed

• Vises and bench dogs for holding work pieces

Tool Storage

Storing your tools properly not only keeps them in good working order, it also makes your shop more efficient and reduces frustration. There are many tool storage options - choose a mix that fits your needs:

• Wall-mounted pegboard for frequently used hand tools

• Horizontal and vertical sheet goods racks for lumber and plywood

• Rolling tool chests for mechanics tools, bits, blades, etc.

• Cubbies or shelves for power tool storage

• Cabinets for finishing supplies and other chemicals

• Drawers for hand tools, hardware and small items

• French cleats for custom hanging storage

Machine Placement

As mentioned, placing your large tools and machines thoughtfully can make a huge difference in your shop's flow and efficiency. In addition to the workflow tips above, consider:

• Infeed and outfeed space needs for each machine

• Placement of dust collection ducts and floor sweeps

• Storing machine accessories nearby for quick access

• Allowing space to move between machines with long stock

• Creating dedicated stations for certain tasks like sanding, finishing, sharpening, etc.

Sound Dampening

Most shops are noisy places, but there are steps you can take to reduce sound for both your own comfort and the consideration of your neighbors. Some sound dampening ideas:

• Use sound-absorbing materials on the walls and ceiling like acoustic panels, foam or hanging baffles

• Insulate the walls to dampen sound transmission to the outside

• Place noisy machines like planers and routers as far from living spaces as possible

• Build an isolated inner room for your air compressor and dust collector

• Use curtains or screens to dampen noise between shop areas

Personal Touches

Your shop should be a place that inspires you and where you enjoy spending time. Don't neglect adding personal touches that make the space uniquely yours:

• Paint the walls a color you like

• Hang inspirational posters, project plans or photos of your work

• Include a comfortable seating area for planning or taking breaks

• Set up a sound system to enjoy music or podcasts while you work

• Display some of your favorite completed projects

• Add plants for a pop of nature and better air quality

• Make it a space you love!

Key Takeaways

• Building a shop starts with determining your goals, budget and location

• Shop layout should be based on workflow, tool placement, safety and storage needs

• Essential shop features include lighting, electrical, ventilation, heating/cooling and plumbing

• Customized workbenches, proper tool storage and strategic machine placement increase efficiency

• Sound dampening and personal touches make your shop more comfortable and inspiring

• With careful planning and attention to detail, you can build a shop that's perfect for your needs!