Woodshop update – wood storage inside the woodshop

Now that the new wall is installed in the shop, it was time to take care of the other three interior walls.

But first, a little history.

Back in 1989 when my late wife and I were stationed at Kadena Air Force Base, Okinawa, we decided to purchase some very nice Rosewood furniture.  Part of that purchase was this beautiful, hand-made Rosewood entertainment center.  My late wife loved this piece.  I kept our TV in the center console, and our stereo equipment along the right hand side.  She kept several beautiful knick-knacks in the left hand side and in the top shelf, behind the glass.

We also purchased a Rosewood curio cabinet, Japanese-style dining room table, and two nightstands.  I still use the nightstands, and I have the curio cabinet in my computer office.

But the old style television is out, and now HDTV, with 1080i and 4k and 8k resolution are the new thing.  The entertainment center was designed for a 4:3 aspect ratio television.  The new televisions are all 16:9 aspect ratio, and just won’t fit in a slot designed for a 32 inch television – which was considered to be “big” back in the ’80’s.

So when I moved into my new Harvest House, the entertainment center was banished to the garage.  Which is now my woodshop.  And it was there holding up a wall that I wanted to use for wood storage.  What to do?

I really tried selling this piece.  We paid over $3,000 for it new and delivered to our home on Kadena.  If I could have received half of that, I would have sold it.  But there were zero takers.  I advertised it for over a year back in 2005, and again in 2010.

But I wouldn’t sell it for less than $1,000.  Why?  Because there’s more than $1,000 worth of Rosewood there!  And as a woodworker, I have a use for interesting and expensive hardwood!

So with apologies to my late wife, I disassembed the entertainment center.

It was sitting against the wall of my shop that I wanted to use for wood storage.  Apologies, I didn’t take a photo of that wall beforehand.

That wall had a long shelf installed over the top of it by the previous tenant.  Since the tenant couldn’t find any studs behind the stucco walls, he chipped out the stucco, leaving several large holes to which he attached shelf brackets to the studs.

Here’s an image of those brackets, and a large selection of disassembled entertainment center.

How much wood?  I have about 300 pounds of wood, ALL ROSEWOOD, from my entertainment center.  I’m already planning projects for it.

But first I had to fix this wall.

The first thing I did was remove the brackets, and the weird wood plugs that the previous owner installed for some reason I don’t understand.

The studs behind the bracket are fine, and are true 3×4 inch studs – not the 1.5 x 3.5 inch studs that are sold at Lowe’s or Home Depot today.

But the previous owner had broken through the stucco, the wire, and the lath behind the wire, leaving a gaping space between the walls to expose these studs.  To fix this, I added a sheet of drywall with stucco wire stapled to it, then a layer of ready-mix stucco on top.  The hole was somewhat deep, so I had to put the stucco on in layers over several days time to allow for drying.

Finally, there was some cracking, but I used Dap DryDex spackle to fill those in and sanded it all smooth before painting it.

After the paint dried, I installed two courses of studs horizontally to the rafters.  These were to offer support to the five 4×4 posts that I installed from floor to ceiling.

These 4×4’s offer the structural strength to my wood storage rack.  According to my math (thanks college physics!) most of the weight will be directly down the 4×4’s to the ground – and these posts can each support tens of thousands of pounds.  The storage rack arms will act as a lever arm to the structure, and try to twist it out of shape.  But fastening the tops of these posts to the building structure will prevent that from happening.  Since my rack will never have more than 1,500 pounds of wood on it, this twisting force is only a portion of that.  The building is well capable of handling a sideways force of a couple hundred pounds.

On each 4×4 post, I’ve placed two or three shelf brackets.  The row along the top is using a standard metal shelf bracket capable of supporting 80 pounds each.  This supports a 2×4 that is butted to the post.  I’ve fastened the top side of the 2×4 to the post using hardened steel angles.  This creates a 24 inch-long bracket for long wood planks.  Each bracket easily supports 100 pounds off of its end without bending, and I can chin myself from each of these brackets near the post.  (And I’m not light!)

Under that I use two 2×6 boards, 30 inches long, to create the second bracket.  Each set of boards is connected to each other by 2×4 standoffs, and is connected to the post with 4 inch lag screws with a sheer strength of over 600 pounds.  There are 4 lag screws per bracket.

The final row of brackets is the same as above, but only 24 inches long.  And it doesn’t cover the whole distance because I want to use the space where the wall power socket currently is.  (I’ll put a shelf and my grinder there.)  I can comfortably walk under the middle range of shelf brackets.  And my rolling sheet wood storage assembly parks under the lowest brackets, so that I’m not tempted to walk under those and brain myself on them.  

In the space between the 4×4 posts, I’ve created an area to store sheet goods off the floor.  I use a bungie cord hooked into eyelets between the posts to keep the sheet goods from falling over.  This area is good for sheet goods that are 30 inches by 60 inches max.

As you can see, I’ve got a lot of wood on the rack already.  I use the top rack for long, one-inch thick pieces that I use for my bookshelves.  The middle area is holding about 200 pounds of Rosewood, and the bottom bracket is being used for 2x4s and 2x6s, and a couple of 4x4s.

The whole thing stores an amazing amount of wood!