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New Shop in the Raw #2: Continuing Build of Miter Saw Station

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Blog entry by builtinbkyn posted 11-22-2015 04:09 AM 3164 reads 1 time favorited 15 comments Add to Favorites Watch
« Part 1: New Shop in the Raw Part 2 of New Shop in the Raw series Part 3: Much Needed Clamp Rack »

Whew! Finally figured out this whole blog series thing :O

Yesterday and today was all about building the casework for the miter saw station. Realizing that the floor is less than even across it’s surface, not level from side to side and the casework is almost 10’ long, I decided to make the assembly in three parts. This will allow me to use leveling feet on each cabinet to compensate for the unevenness of the floor across the length of the whole assembly. I’ll first level the cabinet that holds the miter saw and then level the wings on either side to that. Then the whole thing will get bolted together.

Here’s what I accomplished over the last two days. The tops still need hardwood edging and the drawers are yet to be started. Hopefully I can finish this by mid-week so I can put away some tools and clean up the space.

-- Bill, Yo!......in Brooklyn :)



15 comments so far

View NormG's profile

NormG

5499 posts in 2463 days


#1 posted 11-22-2015 05:26 AM

Coming right along, congrats on the progress

-- Norman - I never never make a mistake, I just change the design.

View builtinbkyn's profile

builtinbkyn

651 posts in 400 days


#2 posted 11-23-2015 11:52 PM

Thanks Norm. Progress has been slow, but progress is progress :)

Only had a few hours available to spend in the shop today, so little was accomplished.

I purchased some threaded inserts and elevator bolts to deal with leveling the cabinets. Used 3/8” x 2.5” bolts for this. After moving all of the tools that were stashed against the wall I moved the cabinets into place to see what I was working with. Sure enough I was able to see how uneven the floor really is. I got the inserts and bolts installed and leveled the units. Then I trimmed up the tops on the wings so they’re ready for hardwood edging. Last step will be to make a decision on the miter saw that will occupy this station.

I have a 12” Ridgid and an 10” Kobalt, both of which require substantial space behind the saw for the slide bars. I think I’ll go with the Northern Tools Ironton, which requires no space behind it for the sliding action. Never saw one in the flesh and hate buying something I haven’t fondled, but I don’t feel the need to spend twice as much on the Bosch.

I’ll need to alter the center cabinet as I’ve changed how this station will work. My initial intent was to make secondary in-feed/out-feed tables that would mount to the cabinets tops. Since the cabinets are already 33” high, I don’t see the need to do it this way. I’ll drop the top shelf of the center cabinet that will support the saw, down about 4 inches, which should be suitable to accommodate pretty much any 10” miter saw. Then the cabinet tops will serve as the in-feed and out-feed surfaces. The last piece I need to make is the fence that will go to either side of the saw – oh and the drawers, shelves and cabinet doors too :)

-- Bill, Yo!......in Brooklyn :)

View nmdusty's profile

nmdusty

9 posts in 378 days


#3 posted 11-24-2015 12:04 AM

Looking good. I dealt with uneven floors in shop in a similar fashion.

I hope you are enjoying the process as you go. You’ll have a nice place to work. My wife and I like Brooklyn- our oldest lives about 2-1/2 miles from Williamsburg

Steve

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builtinbkyn

651 posts in 400 days


#4 posted 11-24-2015 12:16 AM

Hey Steve. Very much enjoying my farting around in a shop that will produce nothing more than self-indulgent sawdust :)

I live about 4 miles from Williamsburg and it took me 45 minutes to get home tonight :( Was heading home a bit earlier than I normally would have to make the Rangers game at the garden, but am now watching it on TV. Didn’t really feel like busting my butt to get there after that ride home.

Yeah Brooklyn seems to be one of the “in” places to be for the younger crowd, of which I am not LOL I’m not old, but I feel that way walking around my neighborhood.

-- Bill, Yo!......in Brooklyn :)

View builtinbkyn's profile

builtinbkyn

651 posts in 400 days


#5 posted 12-05-2015 01:54 AM

This morning I replaced the expansion tank on my tenants boiler and installed an automatic feed water valve. So the morning was pretty well shot. Then it was off to the shop for the afternoon. I was able to get a little more work done on the miter saw station in the few hours I had there.

I made some design changes. Like many, I have a whole bunch of those little plastic boxes with screws, bolts, washers and all kinds of stuff. They’re all different sizes and shapes, don’t generally stack well and just take up a lot of space. Then when you need something, you end up pulling half of the boxes out looking for what ever it is you need. So I decided to use some of the space in one of the cabinets for dedicated storage of these materials. I have a few Stanley storage boxes and figured I’d make them part of this cabinet so they’re readily accessible. I ordered a few more so that will give me ten – 6 shallow and 4 deep. That should be adequate to hold what I have and will ever need. Just waiting on the Amazon delivery for them and then I can consolidate everything.

Then I ripped some maple to 1/4” to edge band the face of the cabinet. Man am I looking forward to that Delta. The 4100 isn’t the best saw for doing this. The fence racks a bit and well between the blade marks and some blade burns, I’ll have a bit of sanding to do. But all in all, I think this is finally coming together.

They’ll be a few drawers on top and possibly one tall drawer below for storing my Bosch 1617 router, so I don’t have to keep pulling out that big blue box. I think there will be just enough room for it and the plunge base. If not that will become three separate drawers. I’ll take some measurements tomorrow.

I should get most of the rest of this done over the weekend. I want to finish this and get it in place as the Delta is in NJ and should be delivered by Tuesday :)

-- Bill, Yo!......in Brooklyn :)

View builtinbkyn's profile

builtinbkyn

651 posts in 400 days


#6 posted 12-10-2015 04:40 AM

Not much progress today. Installed the doors and hardware for the cabinets and cut, assembled and installed the drawers on the right side cabinet. Thought I’d also get the drawer fronts done as well, but it got late and I was hungry :)

-- Bill, Yo!......in Brooklyn :)

View builtinbkyn's profile

builtinbkyn

651 posts in 400 days


#7 posted 12-10-2015 11:35 PM

Well there’s been a setback in completing the miter saw station. Seems UPS lost the Bosch somewhere between the UPS depot here in Brooklyn and my house. I’ve been tracking it since the shipping confirmation email was received. It arrived in Brooklyn on the 5th. However there was no delivery estimate. I thought that was odd, but just chalked it up to the time of year and the amount of packages that were going thru the system.

I then kind of forgot about it until this morning and figured I’d call CPO, where I purchased it from, to see if they had any better info on the whereabouts of the saw. No go. They said they’d file a lost claim and either refund me or ship me another “when available”. The one I purchased was factory reconditioned and the last one they had. It was $520 shipped. So I told the customer service agent I didn’t want a refund and I wanted them to honor the purchase price. After being on hold for 5 minutes or so, she got back on and said they’d send me a new one at the same price. I’m still waiting on the confirmation email for that to happen.

I’m pretty disappointed, but hopeful this will get resolved soon. I can’t finish the saw station without the saw. Need to know the exact height for the fence and so on. Today I just finished up the drawers and called it a day. I should have put some finish on, but was discouraged and tackled some other stuff here at home.

Here’s the finished, unfinished cabinetry.

Last night I devised a plan to move the Unisaw by myself. I picked up the materials I’ll need and will post this in a separate blog entry. Back in 1991 I believe, I was involved in a project to replace a large chiller in One Penn Plaza in Manhattan. It was actually a pretty interesting project that involved a very large helicopter lowering the chiller down near the side of the building where it was pulled in thru the side. We removed a section of the skin of the building to do this. The unit was lowered onto casters, massive casters and rolled to it’s final resting place. However it had to be lowered to the floor of the machine room, just as my Unisaw needs to be lowered from the furniture cart. I’ll employ the same mechanics we did for the chiller. Stay tuned :)

-- Bill, Yo!......in Brooklyn :)

View builtinbkyn's profile

builtinbkyn

651 posts in 400 days


#8 posted 12-18-2015 03:07 PM

Was back at it yesterday, working toward completing the saw station. The Bosch finally showed. We actually two showed. The original factory reconditioned I ordered and a new one that CPO sent when the first appeared to be lost. I have to say, Bosch isn’t doing themselves any favors in how they package these things. The reconditioned saw showed up in a ratty box stuffed with bubble wrap – a box that was not suitable for the saw. The new one showed up in the retail box and well, the pics below tell the story. All I can say is, it took two saws to get one complete, working version.

Here’s the reconditioned saw still in the box and the packaging.

Here’s the reconditioned saw condition.

And here’s how the “new” saw arrived.

So I needed to make a Frankensaw from the two in order to have one complete saw without any broken parts. :O

I haven’t yet contacted CPO to ask them what should happen with the broken saw, but they’ll have to make arrangements to have it picked up and at my convenience. This was not a good buying experience and Bosch should be concerned. Seems they are having difficulty delivering these saws without issue. The dust port should not be installed for shipping and should be placed in the box for the user to install. I’ve read quite a lot of them arrive the way mine did.

Hopefully I’ll finish up the miter saw station in the next day so I can move on to other things.

-- Bill, Yo!......in Brooklyn :)

View builtinbkyn's profile

builtinbkyn

651 posts in 400 days


#9 posted 12-19-2015 01:16 AM

A couple of hours in the shop today were spent making the in-feed/out-feed tables. I made a few changes to them midstream. Another LJ poster made some storage drawers that fit under the tables and thought that was an excellent idea. Storage is always a good thing in a shop. So it took some re-cutting of plywood to make this change.

I also decided to use HDF on the table tops. It will take more abuse from lumber and is a bit more slick than MDF. I also got to use one of my CL finds on the fence pieces. I picked up the Grizzly bandsaw and a Ridgid oscillating belt/spindle sander for $350. Thought that was a pretty good haul for the money.

Nothing is sanded or finished, but I’m getting there. Would be nice to spend a whole day in the shop so I could really get this finished up. I’ve been using the Delta as an assembly table which I really hate doing. However it’s the only large, flat surface aside from the saw station, which I was working on. Another reason to finish up this saw station – so I can get to making a real work bench.

A few pics of the progress.

I have come to the realization, I need more parallel clamps and maybe some shorter ones at that :O Could only glue up one fence at a time and then had to wait until they were set in order to do the next.

-- Bill, Yo!......in Brooklyn :)

View builtinbkyn's profile

builtinbkyn

651 posts in 400 days


#10 posted 12-20-2015 12:36 AM

Another day and a little more progress. Just need drawer fronts, pulls and to put some finish on it all.

Half of my time in the shop today was cleaning and organizing. Oh and trying to find stuff that is still stashed in rubbermaid containers. But tomorrow is another day – in the shop :)

-- Bill, Yo!......in Brooklyn :)

View builtinbkyn's profile

builtinbkyn

651 posts in 400 days


#11 posted 12-22-2015 12:43 AM

Small update. Not much was done over the past few days. Man Christmas is really getting in the way of progress :) but I did manage to sand all the casework in prep for finishing, cut the dados for hardwood drawer glides and cut and profile the drawer fronts. Waiting on delivery of some nice recessed black ring pulls for these little drawers.

Made a small jig to cut the drawer profile.

-- Bill, Yo!......in Brooklyn :)

View RustyHacksaw's profile

RustyHacksaw

82 posts in 723 days


#12 posted 12-22-2015 01:49 AM

I enjoyed reading along. Thanks for sharing.

View builtinbkyn's profile

builtinbkyn

651 posts in 400 days


#13 posted 12-24-2015 03:26 AM

Hey Rusty. Thanks. Posting here to keep me on track and to get input from LJs that will help guide me when I get lost in the weeds LOL

The miter saw station is finished except for the small drawers that go under the in-feed/out-feed tables. It got late this afternoon and was too tired to tackle them. However I did make a template to cut the recess for the pulls and modified a lucite router base to fit my Ridgid palm router, so I could fit it with a bushing.

Guess I’m out of shape. Sanding and applying finish wiped me out. I’ll post the complete project, well, when it’s completed. Hopefully tomorrow. But here’s some random pics of the process, for the record.

Yeah that’s a throw-away brush I used for the finish. Have to say the Basic Coatings waterborne finish went on and leveled beautifully, even with that brush.

-- Bill, Yo!......in Brooklyn :)

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builtinbkyn

651 posts in 400 days


#14 posted 12-24-2015 08:47 PM

Guess this will be my last update to this blog entry on the miter saw station. I have about an hours worth of work left to install the ring pulls on the small drawers under the fence tables. The template for them is made. I just need to cut the recesses and screw them on. I’ll then post the completed saw station as my first project.

Today I reassembled the cabinets, fence/feed tables and drawers after allowing the clear finish to dry overnight. Everything was then finish sanded and waxed. I also installed the Kreg fence system, but didn’t have time set the Kreg tape measures on the top of the fence tracks. It’s Christmas Eve and it was time to head home.

Here’s a handy jig to mount doors when there isn’t another set of hands around to help. Makes the job much easier and less frustrating.

Here’s the whole thing ready to rock and roll.

I love the storage this unit provides. I’ll plan on making an accompanying cabinet that will be part of the cabinet saw out-feed table. That should give me all the storage I’ll need for a while.

PS I’ll be making some kind of dust collection hood for this, but the details are still in the works :)

-- Bill, Yo!......in Brooklyn :)

View builtinbkyn's profile

builtinbkyn

651 posts in 400 days


#15 posted 12-27-2015 12:54 AM

Well it wasn’t quite my last update to this blog entry. Today I added a sliding tray for a battery charger and batteries for my drills.

I also started on the ring pulls for the little drawers, but ran short of time to finish. They’re small, but certainly take time to do, especially in hard wood. If it were pine, I probably would have finished :)

Three more left and then the drawer fronts need to get clear finish applied.

I should have just gone with button pulls :) but thought that they might be an issue when sliding cutoffs off of the outfeed table and onto the lower table. Figured I’d probably break one and have to do the recessed pulls anyway.

-- Bill, Yo!......in Brooklyn :)

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