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Table Saw Mobile Workstation #6: Finishing up

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Blog entry by Greg Wurst posted 2279 days ago 15625 reads 31 times favorited 20 comments Add to Favorites Watch
« Part 5: Top's done - finally! Part 6 of Table Saw Mobile Workstation series no next part

Here is the last segment on my mobile workstation. Overall I’m very pleased with it, but I would definitely make some changes if I had to do it again (due mainly to my screw-ups, not a problem with the design).

First, as many of you know a typical contractor saw has a large number of gaping holes that make dust collection difficult. I used some 1/8” hardboard and magnetic vent cover sheets to block most of the holes. The back’s attached with velcro so it can be removed if I need to make any bevel cuts. Since 99% of my table saw cuts are straight cuts it shouldn’t be a big deal. This definitely made a difference and now most of the dust gets sucked into the vacuum instead of blown across the garage. You can also see the power switch I took from my router table in the basement. I use it for both the table saw and the router (of course, you probably want to turn whatever device you’re not currently using off).


As I mentioned before, I had a ton of laminate left so I went ahead and laminated the door fronts.

Here’s the router attached to the insert and a hole in the back for the power cable.

Attaching the hinges to the door fronts. Let me take a moment here to mention what a poor choice these hinges were for the doors. They really need more than 3/4” to attach to the frame, since it leaves a small gap by the hinges. I had to cut the doors down to fit. They also offer about zero adjustability. If this wasn’t shop furniture I’d have gone with an inset adjustable hinge and redone the doors.

Doors and drawer fronts attached. I attached the drawer fronts with double sided poster tape and then drilled holes in the back and screwed them together. I also cut down all the drawer fronts since my initial design had everything pretty-much gapless and I didn’t really want to try to achieve those tolerances. Here you can also see I’ve leveled the table saw with the top. I used a piece of 1/8” hardboard and 1/4” oak ply along with a washer or two to shim the table saw flush.

Here’s one of my screw-ups. I failed to take into account the fact the fence rails sit lower than the top and block the top doors and drawer. I cut the doors and drawer to clear the fence and attached the cutoff piece with magnetic catches to maintain a somewhat consistent look. I cut the pieces on the bandsaw to minimize the curf. It worked-out ok, but I’d recommend measuring better in the future. ;)

Here are some pics of the finished workstation. I got the pulls at Lowe’s for $.28 each on clearance, and they happen to match the hinges on the doors.

Here’s the back. The extension top was another oops of mine. I didn’t take it into account when I initially designed the workstation, so it would initially be too long to fit under the outfeed table with it attached. I had to remove the two triangle braces and redrill the hinges to allow it to sit flush to the side. I then attached a triangle brace to the back that flips forward and holds-up the top. It works pretty-well, but the extension can’t maintain a ton of weight. It shouldn’t be a problem with what I use it for.

A shot of the router table in use.

Workstation stored under the outfeed table and out of the way.

Overall, a great project and I’m glad I built it. Here are the Sketchup files and material list in an Excel file:

Cutting Diagram

Dimensions

Workstation

Material List

A couple notes:

1. The design is setup for 3/4” material. If you use 3/4” ply for the base like I did you’ll need to adjust the measurements for the 11/16” material for the base.

2. Pocket screws aren’t enough to hold the 2×4 bottom together. The material is just too soft. I had to glue and clamp it as well as use pocket screws. That is the only thing glued on this workstation (except for the laminate).

3. You may want to cut-down the drawer fronts and doors since I left no gap in the design.

4. Of course, you’ll probably need to resize everything to fit your particular circumstances.

If you have any questions or comments let me know.

Thanks,

Greg

-- You're a unique and special person, just like everyone else.



20 comments so far

View Scott Bryan's profile

Scott Bryan

27251 posts in 2449 days


#1 posted 2279 days ago

Nice job, Greg. You have added a nice piece cabinet to your shop that combines a number of functions. I particularly like the addition of the downdraft table. I am looking into either (1) replacing my saw or (2) adding something similar to this. My Craftsman saw just isn’t as functional as I would like it to be. Something like this would certainly improve it.

Well done and thanks for the post.

-- Challenges are what make life interesting; overcoming them is what makes life meaningful- Joshua Marine

View John Gray's profile

John Gray

2370 posts in 2512 days


#2 posted 2279 days ago

I’m impressed!!! GREAT idea and job. Keep up the good work!!!!!
PS – I can’t get your cutting diagram, materials list….ect. It opens the link but no “pictures”.

-- Only the Shadow knows....................

View Greg Wurst's profile

Greg Wurst

781 posts in 2459 days


#3 posted 2279 days ago

For the files, click the download link above the file name at the Windows Skydrive site.

-- You're a unique and special person, just like everyone else.

View teenagewoodworker's profile

teenagewoodworker

2727 posts in 2395 days


#4 posted 2279 days ago

this came out great. i think that i got some good ideas for mine! thanks for the post!

View Mark Shymanski's profile

Mark Shymanski

5078 posts in 2339 days


#5 posted 2278 days ago

Thank you very much for an incredible post! A great project and very useful SU Excel files, thanks! A job well done.

-- "Checking for square? What madness is this! The cabinet is square because I will it to be so!" Jeremy Greiner LJ Topic#20953 2011 Feb 2

View hasbeen99's profile

hasbeen99

183 posts in 2166 days


#6 posted 1800 days ago

WOW. Thank you so much! A table saw/router cabinet is definitely in my not-too-distant future, and I really appreciate your design and willingness to share. Awesome job!

-- "The only thing that counts is faith, expressing itself in love." --Galatians 5:6

View PurpLev's profile

PurpLev

8476 posts in 2275 days


#7 posted 1800 days ago

looks fantastic! I take it you don’t tilt the blade on the TS?

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View Greg Wurst's profile

Greg Wurst

781 posts in 2459 days


#8 posted 1800 days ago

When I need to tilt the blade I remove the dust shields and such. One day I’ll build something that will move with the trunions.

-- You're a unique and special person, just like everyone else.

View Beginningwoodworker's profile

Beginningwoodworker

13337 posts in 2300 days


#9 posted 1761 days ago

Nice work!

-- CJIII Future cabinetmaker

View a1Jim's profile

a1Jim

112011 posts in 2204 days


#10 posted 1755 days ago

This came out Great

-- http://artisticwoodstudio.com Custom furniture

View pete79's profile

pete79

154 posts in 1767 days


#11 posted 1745 days ago

Greg – this looks great and gives me a lot of ideas. How did you do the dust collection set-up for the saw itself? I saw in an earlier picture that you attached a 90 degree elbow to the hole cut in the ply that the saw sits on, but I can’t tell how you then attach that to the shop-vac. I’m working with almost an identical situation and am looking for ideas.

-- Life is a one lap race.

View Greg Wurst's profile

Greg Wurst

781 posts in 2459 days


#12 posted 1745 days ago

The elbow was attached to a 4”x 2 1/2” adapter that pokes-out a hole in the back. I’ve now removed that and attached a 4” quick disconnect.

-- You're a unique and special person, just like everyone else.

View Dandolion's profile

Dandolion

6 posts in 1138 days


#13 posted 1138 days ago

I was discussing a project like this with a friend of mine and he cautioned me about putting a table saw on wheels. I have been thinking about some sort of lift jack system to have wheels that retract and can be brought back down. Though all of the mechanisms that I can think of take up more space than I would like. How do you keep this table from moving when you use it? I think I am going to build a version of this very soon.

View Greg Wurst's profile

Greg Wurst

781 posts in 2459 days


#14 posted 1138 days ago

The thing weighs a metric ton and doesn’t budge. I don’t even lock the wheels. Once it’s rolled into place it doesn’t move even slightly.

-- You're a unique and special person, just like everyone else.

View RibsBrisket4me's profile

RibsBrisket4me

1376 posts in 1132 days


#15 posted 922 days ago

Greg, that is the nicest tablesaw workstation I have ever seen!

-- http://www.PictureTrail.com/gid6255915

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