Simple Storage Rack for Cordless Power Tools
This past year I decided to expand my tool set and began purchasing a variety of cordless power tools. In my case I opted for the Dewalt brand, which allowed the batteries to be used on all tools. When purchasing these tools, Dewalt usually provides a "storage bag" which is handy when transporting tools to and from work locations. In the beginning, this worked fine when all I had was a regular drill and an impact driver. Then came the the reciprocating saw, and then the circular saw, and then ... well, you get the idea. Soon, I had bags with the tools inside stuffed in any storage location I could find. I even purchased a plastic storage cabinet thinking I could set the tools in there without the need of the bags.
Well, after purchasing a cutoff grinder and an oscillating multitool, organizing all these tools, batteries, chargers and accessories for easy access became a challenge.
Thanks to the wonderful world of Pinterest, I began searching for a storage solution that would work for me. I wanted a way to hang all the tools in a manner that allowed easy access. I found multiple concepts in Pinterest, but none seemed adaptable to my garage setup. It was time to begin sketching out a plan that I could make.
Step 1 - Creating the Concept
1st step was to hop on Microsoft Word, and use the drawing tools to layout a concept which would allow me to "hang" each tool. I even included a shelf on top where I could place spare batteries and chargers. I laid out the tools on my office floor to get a sense of the dimensions I would need.
I decided to "sleep on it", and finalize plans the next day.
I have a talented friend (Dr. Marty Averill) who has a fabulous workshop and can do just about anything you want. It can be wood, it can be metal, or it can be a combination of both. After visiting with him about what would be the easiest solution, I scratched my original "metal concept" with shelf for a simple "wood design" without a shelf (I could always add that later).
Step 2 - Layout
I happened to hit Dr. Averill at the right time. He said "do you want to make it now"? So off we went. Using a scrap 48 inch 1x4 piece of wood, we laid out all the power tools on it, and marked locations where we would place 3/8" wooden dowels that would support each tool just beneath the portion where the battery is attached. Laying each tool out on the wood allowed us to place adequate spacing not only for the tool, but also to be able to grab it without hitting an adjacent tool.
Step 3 - Fabrication
The next step was to select the appropriate dowel size to use. I was concerned that the dowels, over time, would sag from the weight of the tools. I was assured by Dr. Averill that 3/8" dowels would be more than sturdy enough, so we began drilling 3/8" holes thru the 1x4 wood board in the marked locations. A drill press was used for drilling, providing consistent, perpendicular holes.
Once the holes were drilled, the 12" long 3/8" diameter dowels were cut to 4" lengths (6" for the circular saw supports) using a chop/miter saw, Then, the ends were slightly sanded to facilitate the dowel insertion into the 1x4" board. I should note that wood glue was added to the dowel end, assuring a strong bond to the 1x4 board. A soft face hammer was then used to tap each dowel in until it was flush with the back side of the 1x4 board.
The final step was to drill holes that would align the wood board with the 16" on center wall studs. Two holes for each stud were drilled.
That's it! Done! Had we not had to run to the big box store to buy more dowels, this tool holder project would have been done in less than an hour.
Step 4 - Painting
I wanted to give the tool holder a paint job, so it would blend in better with the 4' x 4' peg board I had mounted on my garage wall. I purchased a can of matte black spray paint, making the painting a simple task. Normally, it would be. However, being December in Iowa, and not wanting overspray in my garage or my basement, I'd have to do the painting outside. Worried about spraying in 30 degree temps, I scoured the internet to see what others had to say about that. In a nutshell, if you warm up both the spray paint and the item to be sprayed, you can paint outdoors if you work fast, and let the part and paint warm back up between coats of paint.
After fashioning a wire hand hold thru the mounting screw holes, and taking some scrap vent duct set up vertically in the back yard (snow on the ground) to use as a surface to rest the tool holder on, I went at it. After about 10 minutes of spraying, I had a good coat of paint on the tool holder. I grabbed it and carried it inside to let dry in the basement for a couple hours.
Step 5 - Installation
The last step was to mount the tool holder on the wall in my garage. I placed it at the top of the peg board so it would be out of the way, but yet easily enough to reach when I needed a tool. I used deck screws to fasten it to the 2x4 wall studs. I 1st installed a screw in one of the middle studs. Then, using a 4' level on top of the tool holder, I adjusted the board so it was level, and drilled pilot holes into the studs at each of the other mounting locations. Then, using my impact driver, I installed 7 more (8 total) deck screws to firmly attach the tool holder to the wall.
Summary
What started out as alot of consternation on how to store my cordless power tools turned out to be a simple solution, and easy to fabricate! Being an engineer by trade, I tend to over analyze solutions to problems. This was a perfect example. A 48" piece of 1x4 wood, 52" of 3/8" wooden dowels, a can of black spray paint, 8 deck screws and a couple hours of time was all it took to solve my storage problem. Oh, and the excellent guidance from my good friend Dr. Marty Averill!
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