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The His-and-Her Workshop  michael l. maine

Can a husband and wife share the same basement workshop and not drive each other up the wall? Buzz and Nelda Kelly of Indian Springs, Alabama, have been doing it for the past 10 years and couldn’t be happier.

Ten years ago, when Buzz Kelly first Now retired from an information gave serious thought to retiring, he technology career at Birmingham decided to check out a class offered Waterworks, Buzz spends much of by the Alabama Woodworkers Guild. his day in the shop. Nelda works as a His wife, Nelda, offered to drive technical planner for a local bank. “I A pair of 7 x 9' garage doors provides him. They arrived a little early and am so jealous,” Nelda says, referring easy access and plenty of fresh air to Buzz and Nelda Kelly’s workshop. At the the doors were still locked, so Nelda to Buzz’s shop time. “If I didn’t have center of the shop is the table with hung around, just to make sure a really intense, busy job, I’d probably outfeed table and a rolling auxiliary table Buzz wasn’t stranded. She ended up go crazy.” built to the same height. That’s Buzz in taking the class too, and together they Both are avid students of the foreground cutting ; Nelda is discovered a hobby to last a lifetime. . They frequently take in the background at the European-style “I don’t think at that point classes sponsored by the local guild —a favorite work station. “We I realized it would cause such a and elsewhere, learning new skills wish we had two,” Nelda says. Colorful change,” says Nelda about their and then applying them to projects in foam tiles provide an easy-on-the-feet newfound hobby. their own shop. insulated floor surface. Overhead a central Both in their 50s, Buzz and Nelda’s “The good/bad thing about duct attached to the HVAC ductwork routine days are vastly different. both marriage partners becoming carries dust to a central vacuum.

42 woodcraft magazine A p r i l /M a y 2 0 0 8 america’s top shops THE WORKSHOP at a glance Size: 33 x 43' with separate space for wood storage. Construction: Cinder block basement that includes two 3 × 6' windows, two standard 7 x 9' garage doors, and one 2' 8" x 7' exterior door. Heating and cooling: Household HVAC system provides heating and cooling. Lighting: Fluorescent lights; three 8' dual-tube fixtures; seven 4' quad-tube fixtures; two 4'dual-tube fixtures; plus task lighting and magnifying work lamps. Electrical: All the Kellys’ 220-volt Conceding that they needed more workspace, draw from a shop-dedicated Buzz and Nelda opted to close off one of the sub-panel. garage doors and use the space in front as Dust collection: Oneida Super Gorilla a sliding compound mitersaw workstation. A 3-hp cyclone; two jet 1/5-hp air shell around one side captures dust. cleaners rated at 1,044 cfm airflow. The back of the shell functions as a rack, Air compressor: Single-stage Porter- as does one side. Cable rated at 6 hp.

woodworkers is that ALL of the money Interjects Nelda, “What Buzz is “For three years or so, it seemed that goes to the workshop,” Nelda says trying to say is that we are incapable of all we built were shop projects,” Nelda with a laugh. “Another is that a week- following instructions.” recalls. “It’s hard at first. What they long woodworking class becomes a Fortunately for the Kellys, at the don’t tell you is that to build a shop very viable, even attractive, vacation same time their woodworking interests you need a shop.” opportunity.” took off, a relative decided to part with “We’re the other half his tools, so they of each other. We talk bought them. That while we’re working. got them started It’s pretty much with a minimal togetherness time.” investment. First they built a simple workbench made of 2x4s. Next, they moved up They credit their rapid development to more finished- as woodworkers to other guild looking tables for members for willingly sharing their the compound Equipped with multiple and a tray, the knowledge. The best payback, Buzz mitersaw and table European-style workbench serves as one of the shop’s says, “is learning what they’ve done, saw outfeed table, most versatile tools. Storage space is in high demand in

b rian franci s and then graduated and then coming home and using our a shop with two woodworkers. Screws, tacks, and saw tools to perform these skills on our to the European- blades occupy one area; various finishing materials sit projects. Sometimes we tweak what style workbench photo s : on the shelves behind Buzz. we’ve learned to make it our own.” they both love.

w w w . W o o d c r a f t M a g a z i n e . c o m woodcraft magazine 43 america’s top shops

“Things we would change “The good thing is, include buying bigger the first time he does a lot of the around,” adds Nelda. “We bought a gruntwork things while 6" and then a couple of years I am at work. He’s good later replaced it with an 8". Our at sizing and sanding, advice—buy the best equipment you some of the things that can afford. You’ll be glad you did.” are not the fun part of The Kellys go through phases, woodworking, and I really in both the types of projects they appreciate that.” make and the they use. They’ve made projects out of , , cherry, and walnut, but most of the projects—a blanket chest, a barrister bookcase, a lamp, and two Over the years, they have card tables—used . That accumulated a full power-tool was followed by the “walnut phase,” One of Nelda’s current projects collection, including two lathes, says Nelda, when they created such is a walnut spice box with nine inlaid two scrollsaws, a sliding compound pieces as hunt boards and spice drawers. Here she’s using a foot- mitersaw, a , a , cabinets. Currently they are in an controlled tool to a two presses, an 8" jointer, several “ornamentation phase,” which drawer for string inlay. routers, a dedicated mortise machine, involves adding stringing and inlay spindle , belt and drum , into many of their projects. Recently two tables, 15" planer, a couple their matched pair of Federal-style “Those card tables have some of sharpening systems, and numerous card tables earned blue ribbons at the stringing on the tops that wasn’t in hand tools. guild’s annual show. Their favorite finish the original,” says Nelda. “That’s the “They say it takes about $10,000 to is a hand-rubbed oil finish (see Buzz’s thing about making your own stuff. get started, but $10,000 is a drop in the “recipe” below.) All pieces remain in their Each piece is uniquely yours…sometimes bucket,” Buzz says. home or go to friends or family. on purpose.”

BuZZ Kelly’s Show-Stopping finish A patient and meticulous person, according to Nelda, Buzz gets the credit for the show-stopping finish on their projects—a hand-rubbed process that takes about a week.

1. Sand the bare wood to 220-300 grit. 2. flood the wood with boiled linseed oil—HOT. (We use a is small Crock-Pot to heat the oil.) 3. after drying overnight, sand with wet/dry 400-grit using boiled linseed oil as a lubricant to create a slurry. (You can add rottenstone to highlight the grain and help fill open-grain woods.) Wipe the wood dry again. 4. after 4-5 days, scuff-sand with wet/dry 400-grit sandpaper; wipe down. Apply 1 lb cut shellac with Buzz and Nelda won a smooth (Viva) paper towels (one or two coats). blue ribbon for this pair of 5. Scuff-sand with wet/dry 600-grit sandpaper. Use mineral Federal-style card tables. spirits for lubricant if desired. Wipe down and let dry overnight. 6. apply Waterlox sealer with a paper towel. Let dry overnight. Scuff-sand with 600-grit wet/ Buzz’s table is shown with dry sandpaper using mineral spirits for lubricant. (Repeat this step three to four times.) the top open; Nelda’s 7. Scuff-sand with 800-grit wet/dry sandpaper, using mineral spirits as a lubricant. with the top closed. Both 8. Buff with buffing compounds 1 and 2 to medium gloss. convert to full- or half- 9. wax and buff. circle tables.

44 woodcraft magazine A p r i l /M a y 2 0 0 8 The Floor Plan Clamps E Wall-mounted Simple 2x4 dehumidifier bench (built first) Work tables Side clamp rack Window seat

Post 16"band saw Nelda's scroll- Compound saw Tornado room turned sliding into storage mitersaw Belt sander Work Garage door bench Storage 8" jointer cabinets Traditional workbench (built last) N S Outfeed table Stairwell

Shop Refrigerator table Table saw Jigs & fixtures stored under Drum sander stairs Router table Trio of big 8" wall machines Garage door 15" planer play "ring around the Lathe Spindle sander column" Grinder Buzz's Mortise machine

Two drill Dust presses Shelving collector Lathe

Shelving W Router tables

A Common Sense Layout The locations of major tools and dust collector. It is controlled at and other tools—including a pair Buzz and Nelda’s shop layout workstations have changed as the each piece of equipment by a of drill presses, router tables, is constantly evolving. Initially Kellys invested more in their shop blast gate that turns the system compound sliding mitersaw, and confined to one bay of the and refined their skills. However, on and off. A recent acquisition, a scrollsaw—are strategically attached basement-level garage the locations of the four posts the dust collector prompted yet distributed around the perimeter. (the other bay reserved for their lined up through the center of the another reorganization of shop Wood is stored in an attached car), they contemplated building a shop have remained central to the tools. “Before that we had two room that also serves as a separate shop. They decided the workflow (see floor plan above). dust collectors that I put on each tornado shelter. basement shop was so convenient “The posts can’t be moved machine. It was awkward. The Colorful playroom tiles that, instead, they built another because they hold up the house,” (new) dust collector freed up a lot purchased at a local home center garage for the cars. Buzz explains. “So we set the of other stuff,” says Buzz. offer several advantages. They “This way we could take tools around those posts. I ran At the shop’s core is the are comfortable to stand on, have advantage of the heating and cooling all the ductwork and wiring down Powermatic 66 table saw and prevented many a dropped tool from the house,” says Nelda. “There the posts to try to save as much rolling side table along with the from denting or breaking, and is a bathroom at the top of the stairs, space as I could.” adjacent Performax drum sander. provide insulation by covering the and it was pretty easy to put in a Metal ducts extend from the To the right is a 15" mobile planer; bare concrete floor. telephone and rig it with a light that major power tools and up the to the left, a stationary jointer. “In the winter, the temperature flashes when the phone rings.” posts where they connect to main The bandsaw and belt sander are would fluctuate significantly,” says Now the shop occupies the duct wired to the overhead HVAC clustered around the end pole. Nelda. “With this flooring, we have entire former garage space. duct, leading to the Oneida 3-hp Storage shelves, , a 65° constant temperature.”

w w w . W o o d c r a f t M a g a z i n e . c o m woodcraft magazine 45 america’s top shops Smart Ideas for the Taking

Blade safe: This white mahogany blade safe brought order to the Kellys’ blade collection. A joint project they completed several years ago, the safe features 20 drawers. It’s easier to build than it looks. “Simple joinery and a ¼" cutter,” says Buzz. 1

Fig. 1

Plywood guide: Cutting large plywood panels down to size on a table saw can be a bit cumbersome, so Buzz devised this plywood cutting jig. When down, the flip-up shows the exact location of his blade, eliminating a measuring step. “Now 2 I just measure one time, flip the board and cut the line with my saw,” says Buzz. The jig is adaptable to other portable power tools, such as a router and .

Fig. 2

46 woodcraft magazine A p r i l /M a y 2 0 0 8 america’s top shops & 3 4 Panel sled: Buzz built this panel sled years ago when he had to cut a large piece of countertop, and it has been a fixture in the shop ever since. Designed for safety, the sled is constructed of ½" plywood on the bottom and 2 x 6" risers. Wooden runners on the bottom fit into the table saw slots to guarantee smooth, cuts.

Fence support: Another safety device is this simple sliding fence, ideal for cutting stock on edge. The workpiece is clamped to the sliding fence and the cut is made as shown here - fingers well out of harm’s way. “It’s much easier than trying to balance a board on edge, like Fig. 3 when you are cutting a raised panel,” Buzz says. 5

Fig. 4

Tool rack : Although they continue to outfit their shop with new tools, the Kellys occasionally put their old tools to good use. They acquired this lathe and collection of turning tools from Nelda’s brother-in-law. The simple angled stand keeps the tools within easy reach.

w w w . W o o d c r a f t M a g a z i n e . c o m woodcraft magazine 47 america’s top shops Buzz and Nelda’s Toy Build-A-Thon

n 2007 the Alabama Woodworkers Guild donated I7,400 toys to local organizations. Various guild members hold build-a-thons at their home work- shops in the fall as the deadline for completing the projects nears. On Fridays, guild members meet at the local Woodcraft store and use the store’s shop for build-a-thon projects. Cars, jewelry boxes, and game boards are the most common items. Buzz and Nelda host one or two sessions at their home each September and October. On these days, a shop usually occupied by one or two woodwork- ers may see 27 guild members at work. In about four hours they can complete 300 cars and jewelry boxes. Many of the cars are left unpainted so children can them as part of their physical therapy. Toys are distributed among several organizations, including the Children’s Hospital in Birmingham, the Alabama Department of Human Resources, and the Alabama School for the Deaf and Blind.

Jim Harrold, Editor-in-Chief HOW TO SUBMIT YOUR SHOP: Woodcraft Magazine Got a top woodworking shop filled with ideas for smarter woodworking? You 4420 Emerson Avenue, Suite A could be featured in Woodcraft Magazine and earn a $200 Woodcraft gift card. P.O. Box 7020 Parkersburg, WV 26102-7020 Send a short writeup, photos and/or sketches and rough floor plan, if possible, to: [email protected]

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