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Charging Station

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Blog series by Ross Leidy updated 03-09-2021 03:07 PM 8 parts 2919 reads 20 comments total

Part 1: Getting Started

03-01-2021 05:32 PM by Ross Leidy | 2 comments »

Having finished-up my under-bench storage project, I turned my attention to another workshop improvement project – a cordless drill charging station. In the spirit of adding more storage in the shop, I also wanted to incorporate a couple drawers for batteries, drill bits, screws, etc. I looked at a lot of similar projects here on LJ’s for inspiration. No two charging stations were alike, but the layout that made the most sense to me was to have the drills hanging upright at a...

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Part 2: Tool hanger

03-02-2021 12:00 AM by Ross Leidy | 8 comments »

I mocked-up the tool hanger slots by clamping some strips of wood to my workbench. I fiddled with the slot width and the spacing between slots to fit all my existing drills. I arrived at 1-1/2” slot width, which 1-7/8” between slots. (This turned out to be wrong, which I found out later.) With those measurements, I modeled the hanger in my CNC software and cut out the piece from some 18mm baltic birch. The slots looked a little narrow, and sure enough when I tried to fi...

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Part 3: Carcass glue-up

03-02-2021 07:33 PM by Ross Leidy | 2 comments »

I glued-up the carcass in two stages: the top, back, and shelf as a sub-assembly, and once that was dry, I glued the sides and bottom. I just didn’t have enough clamps to do it all at once. Plus, it was important to get the sub-assembly tight and square since it would be providing the rigidity to the cabinet. The assembly squares and clamps came in handy here.

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Part 4: Drawer boxes

03-06-2021 04:36 PM by Ross Leidy | 1 comment »

I’m building very simple drawer boxes here. Just butt joints with dominos for the 1/2” back, front, and sides, and brad nails on the 1/4” bottom. And glue, of course. I assembled the back, front, sides first, then attached the bottoms later.

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Part 5: Makita charger mounting plates

03-06-2021 04:53 PM by Ross Leidy | 1 comment »

I have two Makita chargers that I’ll mount on the side of the cabinet. The unfortunate thing about these chargers is that they have no hanger slots on the back. With some googling, I found some instructions on using the rubber feet like expansion nuts as a way to mount it. I’ll use that idea to attach the charger to a mounting plate, and the mounting plate will attach to the cabinet. As it turned out, the feet positions weren’t exactly the same, but the difference was ...

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Part 6: Carcass finishing

03-08-2021 03:31 PM by Ross Leidy | 2 comments »

I applied some oil-based poly on the cherry edging to bring out the color, and once that was fully dried, I applied some water-based poly on all the exposed surfaces on the carcass and drawers.

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Part 7: Drawer fronts

03-08-2021 04:20 PM by Ross Leidy | 0 comments »

Building the drawer fronts was identical to what I did for the workbench storage project. They’re MDF, edged with anigre, and then veneered on the front with anigre. I cut MDF to the proper width, and applied edging on two sides. Once the glue dried, I trimmed the excess with a flush-cut bit on the router table, with a temporary fence to allow the excess trim to slide underneath. Then cut the edged MDF to the proper drawer height and applied edging on the long edges. ...

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Part 8: Nearly done

03-09-2021 03:07 PM by Ross Leidy | 4 comments »

There’s just a few things left to finish-up and I’ll have a functional charging station. To install the tool hanger, I placed a 3” spacer between it and the top, and screwed the hanger in place through the pocket holes on the underside. I used some double-sided tape to hold the drawer fronts in place temporarily so I could install screws from inside the drawer box. To prevent the drills and drivers from tearing-up the back of the case, I cut a strip of rubbe...

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