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Contractor Saw Cabinet

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Blog entry by Jeremy Greiner posted 11-01-2011 06:02 AM 6754 reads 8 times favorited 29 comments Add to Favorites Watch

This weekend I started on my contractor saw cabinet. This will take me a while to do, I hope to have it done by the end of the year but who knows. At very least I hope to have the saw mounted and usable and ready in another 2 weeks or so. I am continuing is some very large footsteps following zzzdoc and tedth66 design. zzzdoc has a long and wonderful blog entry detailing how his cabinet was built with a lot of help from ted. I hope to continue that and post as much details about my assembly in hopes to aid anyone else who wishes to do build something similar.

I almost feel bad for my current table saw, it’s last job in my shop will be to make the cabinet/stand for my new sawstop saw. Then I’ll have to sell it to make some room in my garage.


Here is the base, I think I made it too big .. my initial measurements were misguided. It’s 7’ by 32’’ .. I think it’ll be long enough but I think it’s too deep, I was measuring out to the edge of the fence, not keeping in mind where my feet will go. But I’m not to worried it will just have some more space in the back then originally intended.

I used 2×4 stock that I’ve jointed and planed flat to 3 1/4’’ by 1 1/4’’ roughly I did this because I was able to get some 6’ long 2×4’s hanging out the back end of my mini. Originally the plan was to use maple but I didn’t have any long enough and wasn’t looking forward to getting more, hopefully this will be sturdy enough, it feels pretty solid. One difference is the base is not 1 solid piece of 3/4’’ plywood, it’s 2 pieces since the 2×4 torsion box area stretched the full length the split doesn’t seem like it will be a big deal.

I drilled the holes for the wheels, then used wood filler on the screw holes and such and sanded everything smooth. 3 coats of lamp black milk paint over the visible areas (saw no reason to paint the inside of the torsion box area) and then 2 coats of wipe on poly over the entire bottom. I wanted to make sure I got the bottom good and sealed so I didn’t have any potential warping issues with moisture being absorbed differently from different parts of the base.


I liked zzzdoc’s idea of filling the recessed holes with epoxy so I did that this evening after the trick or treaters finished testing if my door bell was working. I’ll let the epoxy set overnight even though it says 5 minute and tomorrow I’ll sand the top. I didn’t paint the top yet because I plan on gluing other parts to the top and figured the paint would hurt the glue.

I have some more measuring and planning to do, the next step is to make the base the saw will sit on, it needs to be sturdy and also have it set up for dust collection. The other catch is how low the saw will be, one of the reasons I didn’t go for a cabinet saw is that they sit too high for me, and after the mobile base it would be even higher.

My goal is to have all the planning done this week so I can build the base the saw will sit on this weekend so I can get the saw mounted.

Thanks for reading and I’m always open to suggestions or ideas.

-jeremy

-- Easy to use end grain cutting board designer: http://www.1024studios.com/cuttingboard.html



29 comments so far

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Jeremy Greiner

568 posts in 1425 days


#1 posted 11-02-2011 01:49 AM

I started drawing everything in sketchup, and it turns out I’m pretty hosed, I made the base way to big I really don’t know what I was thinking. Well I do know .. I can show you, here is a picture of the size of my torsion box base, relative to the size of the saw.

Basically I did all my measurements based on the top table it’s the exact same length and width including fence.

So now I’m back to the drawing board, I have the exact dimensions of the saw loaded into sketchup now so I should be able to plan a lot better.

It really is a shame I don’t know what I’m going to do with my current base.

-- Easy to use end grain cutting board designer: http://www.1024studios.com/cuttingboard.html

View zzzzdoc's profile

zzzzdoc

506 posts in 1656 days


#2 posted 11-02-2011 04:58 AM

My base is 70.5” x 25.5”, FWIW.

I’m not sure if the extra depth will present a problem. It will be useful on the router side of the table. You’ll have to make the back of the saw box not at the back of your base, otherwise you’ll run into the motor.

It will be a big behemoth at your size. Is your shop big?

- zzzzdoc

-- Before you criticize someone, you should walk a mile in their shoes. That way, when you criticize them, you're a mile away and you have their shoes.

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tedth66

458 posts in 1843 days


#3 posted 11-02-2011 05:24 AM

Hello Jeremy,
I think you’ll be able to design around the 6.5” wider base. I would cheat that 6.5” to the back of the saw versus the front. zzzzdoc has a good point about the motor potentially running into the box it sits on. For you, you could make the boxes that the saw sits on into four boxes. The two boxes that sit on the base could be deep (6.5” deeper than zzzz’s and my boxes) and the two top halves could be the same depth as what zzzz and I have (~24.5 deep) ~ so it would be two deeper boxes on the platform and two not as deep boxes on the top. The top left box will be the dust collection box and the other three boxes will be drawers…. two deep drawers and one not so deep drawer ~ if that’s in your plans.

I think you’re off to a great start. Believe me, when I built my cabinet, there were more than a couple of times where I had to redesign or rebuilid something. I think it’s great that you’re blogging each step like zzzz did.

-- Ted

View Jeremy Greiner's profile

Jeremy Greiner

568 posts in 1425 days


#4 posted 11-02-2011 06:07 AM

Heya Guys I appreciate the encouragement, and I think I could make it work, but honestly this is something that I want done right and I don’t think I would be happy with it if I just “made it work”. My shop is a 2 car garage, and space is some what an issue, I think the weight would also be an issue that extra space turned into storage = more weight.

I haven’t thrown it away yet, I haven’t made up my mind I’m doing more of the design in sketchup first this time so I have a good idea of what I want.

One difference is I won’t be adding the router table into the side of the saw, I just want to turn that into more shop storage. I haven’t decided on drawers or cabinets or what yet ..

With the actual dimensions of the saw in sketchup it’s a lot easier to plan out, I’ve roughed out the design so far here is what I have. I want to design each of the sub boxes next.

The new designed base is 73 3/4’’ by 24 1/4’’ I want to design the box under the saw first, I am going to design it to hold a 4’’ dustright adapter. I like how zzzdoc designed it to be attached from the side instead of behind so I’m going to try for that.

-- Easy to use end grain cutting board designer: http://www.1024studios.com/cuttingboard.html

View Jeremy Greiner's profile

Jeremy Greiner

568 posts in 1425 days


#5 posted 11-02-2011 07:09 AM

I think I’m pretty close to finalizing the box that the saw will sit on, it’s based on the assembly pictures zzzdoc posted, I doubled up the walls and the top which should make it strong enough.

Here is a view of the box by itself

Here is an exploded view

I need to verify the opening in the center, I read there where issues with moving the saw to 45 degrees so I want to make sure it’s wide enough that the dust shroud doesn’t catch. I also need to make sure that the rotation wheel for the angles on the right hand of the saw won’t get caught up on the plywood.

I would like to find a way to make it so the diagonal portion was on hinges or something I haven’t figured that part out how I would seal it if it wasn’t glued in. But I would like that so I could open up the box and retrieve a wrench when I drop it in there, because you know it happens, all the time.

That’s it for thinking tonight though, now I’m off to bed.

-jeremy

-- Easy to use end grain cutting board designer: http://www.1024studios.com/cuttingboard.html

View zzzzdoc's profile

zzzzdoc

506 posts in 1656 days


#6 posted 11-02-2011 11:28 AM

Yes, dropping stuff is a pain. You can get stuff through the back, or, if your DC piping is easily removable, through the side.

Hinged to give front access is an interesting idea.

-- Before you criticize someone, you should walk a mile in their shoes. That way, when you criticize them, you're a mile away and you have their shoes.

View tedth66's profile

tedth66

458 posts in 1843 days


#7 posted 11-02-2011 02:36 PM

I too have dropped small items down the chute but all I did was reach through the dust port and grab it.

Speaking of dust port, I think you’re making the right decision to put it on the side like zzzz did. The reason I originally put it out the back is because the SS chute points towards the back. About a month ago I added another port to the left side like zzzz. I did this for two reasons, my initial design didn’t have the fold down outfeed table so when I wanted to fold down the table I had to remove the dust hose connection to be able to do this. More importantly, when I’m using the saw, I now position the left side in the direction of my dust collector drop and for efficiency reasons (no bends in the dust hose) I now connect it straight into the left side of the cabinet. I’m going to cap the back port but I’m sure I’ll use it once in a while depending where I position the saw for cutting.

I’m pretty sure you’ll need to chamfer that right edge hole so the chute has some room for the miter cut position. If memory serves me correctly, I didn’t have but an inch of extra ledge from the SS base and after test fitting and modifying, that extra inch turned into almost nothing (only where the chute touched the saw box). I chamferred the heck out of the double top plates. Again I’m guessing because I don’t know exactly where you saw sits on your Sketchup drawings. If you cheat the saw to the left than you might not have to do much to it.

Nice work on the Sketchup drawings. I like your decision to NOT work around the extra large base.

-- Ted

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zzzzdoc

506 posts in 1656 days


#8 posted 11-02-2011 09:50 PM

If you can use 6” instead of 4” for the DC connection/hose, I think it will work significantly better.

-- Before you criticize someone, you should walk a mile in their shoes. That way, when you criticize them, you're a mile away and you have their shoes.

View Jeremy Greiner's profile

Jeremy Greiner

568 posts in 1425 days


#9 posted 11-03-2011 06:01 AM

No goin back now, tore down the first base I should be able use most of the wood again in the new base. I’ll need to get another 2×4 to replace the the sides .. but the longer pieces should be reusable.

I’ve updated the model with updated drawer boxes and added drawers. I still haven’t figured out how I’m going to add a door to the inside dust compartment yet.

As for using 6’’ dust collection, all my stuff is set up for 4’’ right now I use a dust right attachment and attach it to the device I need. I might set it up for 6’’ and use a 6 to 4’’ adapter.

-- Easy to use end grain cutting board designer: http://www.1024studios.com/cuttingboard.html

View hjt's profile

hjt

776 posts in 1791 days


#10 posted 11-04-2011 11:43 PM

Wow Jeremy that is quite a project. Very neat that you know sketch up, but then again, I remember reading that you are a software designer and so that should come easy to you. I look forward to seeing how the project progresses.

-- Harold

View Jeremy Greiner's profile

Jeremy Greiner

568 posts in 1425 days


#11 posted 11-04-2011 11:45 PM

Thanks Hjt,
I should get the wheeled base rebuilt this weekend, once the project is all said and done, or at least I get the sketchup model done I’ll make sure to post it for anyone who wants to use it as a reference for their own project.

-- Easy to use end grain cutting board designer: http://www.1024studios.com/cuttingboard.html

View hjt's profile

hjt

776 posts in 1791 days


#12 posted 11-04-2011 11:56 PM

I Just downloaded SK8 and bought the book SketchUp 8 for Dummies. I enjoy using the computer and do a lot of work on it, but thus far SK has baffled me. But I”’m not giving up.. yet!

-- Harold

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Jeremy Greiner

568 posts in 1425 days


#13 posted 11-08-2011 03:46 AM

Just finished adding a second coat of paint to the rebuilt base, the long pieces that where already painted saved a bit of time and paint so that’s kinda nice, just some touch up paint here and there. Might be able to get the 3rd and final coat of paint on tonight and I can start adding some poly tomorrow. Add the wheels wednesday or thursday .. and friday I can start on the box that will hold the saw.

-- Easy to use end grain cutting board designer: http://www.1024studios.com/cuttingboard.html

View hjt's profile

hjt

776 posts in 1791 days


#14 posted 11-11-2011 04:43 AM

I can see that someday I need to to take a nice ride on my Harley to Apopka and see your shops and learn from you. If not learn wood work… maybe SketchUp!!

-- Harold

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RibsBrisket4me

1376 posts in 1159 days


#15 posted 11-11-2011 04:47 AM

Apopka?? Heck I used to live in Clermont :-) Ate mucho BBQ in Apopka :-)

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

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