Router & Miter Work Station #1: The Design

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Blog entry by MrVitaminP posted 09-29-2010 07:49 PM 3956 reads 1 time favorited 6 comments Add to Favorites Watch
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Recently I decided that my existing miter saw station wasn’t ideal. It is a mobile station and is fairly stable given that it is light and easy to move. But, in truth I rarely, if ever, move it. So, the fact that it is mobile has meant very little. What has mattered is that it is small, too small. Cutting long pieces on it can be a bit of a headache. This was enough of a push to start a new project.

Looking around I have found plenty of inspiration. Using this I came up with a few design goals:

  • Must have a large/long table surface
  • Inset the miter saw so table top is flush
  • Provide extra storage for the shop
  • It must fit along an open wall in the shop

My miter saw, Milwaukee 6955-20, it pretty large and as such requires a fair amount of space. Because of this, I settled on a table depth of about 36”. With such a deep and large table surface it seemed a shame to not multi-purpose the project.

First, I looked at using the table as a secondary assembly station. For this I wanted a level and stiff surface. To accomplish these goals I decided to go with a torsion box design for the table tops. This was inspired by the assembly table design that the Wood Whisperer built a couple of years ago.

Second, I wanted to use this opportunity to build a new router station as well. Maybe, a miter / router station with torsion box top is a little overkill. But, it seemed like it would work.

Ok, enough intro, here is the initial design that I have put together:

Design Diagram - Isometric View Design Diagram - Top View Design Diagram - Front View Design Diagram - Back View Design Diagram - Right View Design Diagram - Left View

These diagrams were put together with Google SketchUp. I am still tweaking the design and these images are missing the table fences.

The design as a whole is split into three main components: router table with torsion box surface, miter saw stand, and storage cabinet with torsion box surface. The torsion box surfaces are designed to sit flush with the top of the miter saw work surface.

As for materials, I am planning on building the cabinets that hold the tables with 3/4” ply. The torsion boxes will be MDF with a hardwood trim to help protect it from bumps. Finally, I was planning on putting a Formica layer on the top surfaces.

Currently, my plan is to finish up the details of the design and work on the actual project over the next few months. Any feedback is always welcome!

-- Pierre, Missouri

6 comments so far

View Rick  Dennington's profile

Rick Dennington

5858 posts in 3192 days

#1 posted 09-29-2010 08:08 PM

I think I may have just the ticket, as far as what your after….take a look at mine in my shop..

-- " At my age, happy hour is a crap and a nap".....

View dub560's profile


615 posts in 2911 days

#2 posted 09-29-2010 09:03 PM

very nice setup

-- Life is enjoyable especially when you borrow from people

View fernandoindia's profile


1081 posts in 2941 days

#3 posted 09-29-2010 09:24 PM

I´ll be following Pierre. This is also a pending mater for me.

What I did already decide, is to have an independent mobile RT.

Rick, that´s clean and tidy. !!! Indeed an inspiring shop .

-- Back home. Fernando

View Gregn's profile


1642 posts in 2981 days

#4 posted 09-29-2010 10:29 PM

Rick, like the way you set up your RAS. Is the top all one piece or is there an insert that can be replaced?

-- I don't make mistakes, I have great learning lessons, Greg

View Rick  Dennington's profile

Rick Dennington

5858 posts in 3192 days

#5 posted 09-30-2010 12:40 AM

Greg, The top is actually 2 pieces. From the left of the chop saw is one piece, and to the right is one piece.. There is no insert to replace….About 2 ft. of fence is replaceable. If I chew it up making any angle cuts (which I have before) with saw and dado blades, it is seperate from the rest of the fence..Haven’t done that in years, though….Like so many on here, I use it for crosscutting only at 90degrees anymore…

-- " At my age, happy hour is a crap and a nap".....

View POGO's profile


19 posts in 2882 days

#6 posted 09-30-2010 03:20 AM

I am working on building my version of a Miter Saw Station which incorporates several of your design criteria elements. Only completed construction of the drawer boxes and fronts and beginning on casework. I decided on the Milwaukee 6950-20 due to the depth requirements for the slider version. The Sketchup model is very detailed compared to most and can easily be adapted and modified for your specific needs.

I investigated the recessed saw design and decided on the elevated stock support due to difficulty in alignment between the Left and Right stock supports and saw table. One unplanned benefit is that the area behind the support section provides for good place for storage and helps reduce clutter which quickly consumes space for stock placement when making measured cuts.

One consideration which I see many versions of Miter Saw Station do not address is what happens should the back fence on saw base need to slide outward to accommodate compound angle cuts. My design calls for replacement of either fence with 4/4 Oak trimmed to fit into exiting fence support channels and minimizes the distance to the Kreg “Trak” mounted atop the backstop. The replacement Oak will provide for support on tall material yet allow for compound cuts.

-- Arvid, Spring Texas

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