Shop Tools

A workshop runs on a short list of well-chosen tools, used well, in a space that lets you work safely. The money is rarely the limit; it is knowing what to buy first, how to measure accurately, how to hold the work still, and how to keep tools sharp, dry and findable. This guide takes the subject in ten pages: planning the space, the workbench, power, lighting and air, measuring, hand tools and marking out, power tools and machines, workholding, drilling and fasteners, tool care, and organizing and buying. Every worked number (bench stiffness, cord voltage drop, drill speeds, thread strength, the cost of a first kit) is computed so that you can check your own shop against it. Workshop-wide hazards are in Workshop Safety; the digital machines (CNC, laser, 3D printer) have their own guides.

Start here: what do you need?

I need to…	Go to
lay out a shop, leave enough room, or stop tools rusting	Planning the Workshop: Space, Layout and Workflow
choose a bench height, build a stiff top, or place a vise	Workbench and Shop Setup
stop breakers tripping, light the shop, or size a compressor	Power, Lighting and Compressed Air
measure accurately, or know how good a caliper really is	Measuring Tools and Accuracy
mark out, saw, file, chisel or deburr by hand	Hand Tools, Marking Out and Cutting
pick cordless tools, set a drill press speed, or choose a first machine	Power Tools and Shop Machines
clamp, hold or locate a part so it stays put	Workholding, Clamping and Fixtures
choose drill and tap sizes, thread engagement or tightening torque	Drilling, Tapping and Fasteners
sharpen an edge, prevent rust, or schedule calibration	Sharpening, Maintenance and Tool Care
organize tools, decide what to buy first, or plan a budget	Organizing, Buying and Budgeting

A suggested order

Start with Organizing, Buying and Budgeting to decide what to buy first, and read Workshop Safety. Then Planning the Workshop: Space, Layout and Workflow, Workbench and Shop Setup and Power, Lighting and Compressed Air set up the space; Measuring Tools and Accuracy, Hand Tools, Marking Out and Cutting and Power Tools and Shop Machines are the working tools; Workholding, Clamping and Fixtures and Drilling, Tapping and Fasteners are how parts are held and joined; Sharpening, Maintenance and Tool Care keeps it all working.

1. Planning the Workshop: Space, Layout and Workflow: Zones and workflow, clearances around machines, floor loading, humidity and rust, noise, and a worked layout for a small shop.
2. Workbench and Shop Setup: Bench height from elbow height, how stiff a bench top needs to be, vise forces, bench types, storage and a worked build.
3. Power, Lighting and Compressed Air: Circuit load and breakers, cord voltage drop, lighting levels, compressor and tank sizing, and dust collection airflow.
4. Measuring Tools and Accuracy: Rules, calipers, micrometers and indicators, resolution against accuracy, thermal expansion, reading technique and an error budget.
5. Hand Tools, Marking Out and Cutting: Layout and marking, saws, files and chisels, squareness checks, hand drilling, deburring and how much force a hand tool really needs.
6. Power Tools and Shop Machines: Cordless battery energy, the drill press, bandsaw, grinder and sander: speeds, torque, what to buy first and how the machines compare.
7. Workholding, Clamping and Fixtures: Clamp force and friction, vises, soft jaws, locating with pins, jigs and stops, and how to hold thin or awkward parts.
8. Drilling, Tapping and Fasteners: Drill and tap sizes, clearance holes, thread engagement, tightening torque, rivets, adhesives and choosing a fastener.
9. Sharpening, Maintenance and Tool Care: Edge angles and honing, grinding without losing temper, preventing rust, lubrication and calibration schedules.
10. Organizing, Buying and Budgeting: Storage and 5S, shadow boards, what to buy first at different budgets, second-hand checks, cost per use and makerspaces.

How a job moves through the shop

Quick reference: numbers and rules

Topic	Number or rule	Page
Bench height	elbow height ≈ 0.63 × stature; heavy work 10 to 15 cm lower, fine work 5 to 10 cm higher	Workbench and Shop Setup
Circuit load	I = P ÷ V; keep continuous loads under 80 % of the breaker	Power, Lighting and Compressed Air
Lighting	300 to 500 lux general, 750 to 1 000 lux at the bench	Power, Lighting and Compressed Air
Walkways	at least 0.9 m clear around machines and benches	Planning the Workshop
Rust risk	metal colder than the room’s dew point collects water	Planning the Workshop
Measuring	resolution is not accuracy; the tool should be ten times finer than the tolerance	Measuring Tools and Accuracy
Drill speed	n = 1 000 v ÷ (π d)	Power Tools and Shop Machines
Vise holding force	Fhold = 2 μ N	Workholding, Clamping and Fixtures
Thread engagement	about 1 × diameter in steel, 1.5 to 2 × in aluminum	Drilling, Tapping and Fasteners
Sharpening	bevel 25° chisel, 30° plane iron, 15° per side knife	Sharpening, Maintenance and Tool Care

Related guides and tools

• Workshop Safety: PPE, fire, fumes, dust, noise and electrical safety.
• CNC Machining: the mill and lathe that a drill press and bandsaw lead to.
• Fits and Tolerances: how fine a tolerance you can hold with the tools you have.
• Structures and Strength of Materials: the beam formulas behind a stiff bench.
• Tap Drill Calculator and the Bolt Torque Calculator.
• Electronics Fundamentals: setting up an electronics bench.

Safety first

• Eyes, ears and lungs first. Safety glasses, hearing protection and a dust mask cost less than any tool and protect what cannot be replaced.
• Keep every guard in place and know where each machine’s stop is. No gloves, loose sleeves or jewelry near rotating tools.
• Hold the work, not with your hands. A clamp or vise keeps your hands out of the cut (see Workholding, Clamping and Fixtures).
• Settings in this guide are starting points. Follow your tool maker’s manual and the rules where you work; have fixed wiring done by a qualified electrician.

FAQ

What should I buy first?

Safety equipment, then measuring tools, then a sturdy bench with a vise and clamps, then a drill and hand tools. Add one machine at a time when a real job needs it. See Organizing, Buying and Budgeting.

How do I choose the height of my workbench?

Start from your elbow height (about 63 % of your height) and lower it for heavy work or raise it for fine work. See Workbench and Shop Setup.

Why does my breaker trip when I start a saw?

Too much on one circuit, or the start-up surge of the motor. Use a separate circuit or a larger breaker with a qualified electrician. See Power, Lighting and Compressed Air.

Are digital calipers accurate enough?

For most workshop work yes (about ±0.03 mm), but resolution is not accuracy and technique adds error. See Measuring Tools and Accuracy.

Where did the old Shop Tools and Workbench pages go?

All of their content is in this guide with much more depth: the workbench and setup page was moved under this overview, and the tools, measuring and workholding sections now have pages of their own.

References

• Oberg et al., Machinery’s Handbook, Industrial Press (measuring instruments, thread data, tolerances, thermal expansion).
• Illuminating Engineering Society, The Lighting Handbook; EN 12464-1, Lighting of work places.
• Pheasant, S. and Haslegrave, C., Bodyspace, CRC Press (elbow height and work height).
• OSHA, Machine guarding and HSE (UK) guidance on woodworking and workshop machinery.
• Greif, M., The Visual Factory, Productivity Press (5S and visual workplace organization).

Last reviewed: October 2026. Figures such as bench heights, lux levels and breaker limits are guidelines: check local electrical codes and equipment ratings, and follow your tool makers’ safety instructions.