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Table Saw and router Work Station

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Blog entry by mark76wa posted 05-04-2012 06:28 AM 5947 reads 4 times favorited 23 comments Add to Favorites Watch

So I’m kind of getting better at wood working. I have out grown my ShopSmith and started looking for an up grade. I was saving up for a SawStop but kept reading posts about misfires and the added cost and started to have second thoughts. I happen to run into a craigslist post from a surplus resale store for a Powermatic 64A w/30” fence for $625. I quickly decided it was too good to pass on so I am the new owner of a cool saw!

I have been watching several contractor saw work stations and really like posts by:
zzzzdoc
http://lumberjocks.com/projects/47610
tedth66
http://lumberjocks.com/projects/27579
phil619
http://lumberjocks.com/projects/49484
And a plan from Shopsmith’s Table Saw Secrets

I want a work station for my 64A with excellent dust collection, mass storage, a router compact foot print, a work bench area and above all else it must look really cool. After looking at all the examples, the one thing I wanted in my work station was to have a router cabinet on the left. I cant see anything that would prevent a design with the router on the left that would interfere with the operation of my saw.

As it turns out the company I work for uses a lot of plywood and I am allowed to take the cut offs. I was able to grab about 5 sheet worth of cut offs ranging from 12×20 all the way to 4’x’4’ sheets of quality 3/4” ply. I also got 3 sheets of 1” ply (I didn’t know they even made that).

So with all that I started cutting up parts. Unfortunately, my shop space is extremely limited so I have not been able to set up the 64A and had to cut all the pieces with my ShopSmith. I put a lot of planning into the initial design and looked to minimize the number of setups. Since many of the parts have similar dimensions I cut all the pieces that had the same dimensions on a side at the same time.

I started with the base and went with a torsion box design and added a 3/4 ply top and 4” casters

Than came the boxes. I have three boxes that are 15-3/4” tall, 21” deep and various widths based on what they are for (router base, saw base and storage). The fourth box is taller so it can accommodate lots of storage.

I am 90% sure the boxes are square but they just aren’t lining up correctly. If anyone has a suggestion on how to fix this I would really appreciate it. Also, I am using the 1” ply for the sides of the box that the saw will sit on. I am contemplating adding a sheet of ply to the top of all thee boxes to tie them together and stiffen the whole thing. What do you think.



23 comments so far

View rockindavan's profile

rockindavan

284 posts in 1356 days


#1 posted 05-04-2012 06:41 AM

As long as the top of the box height isn’t critical, I would put a sheet of plywood across the top to tie everything together. As far as leveling the boxes to each other, you have two options I can see. First is screwing the boxes to the top, and then shimming the bottom of the boxes to your base. The second is to screw the boxes to the base, then put shims between the cracks of your boxes and base. You could nail on a face frame around either to cover up the gaps.

View tedth66's profile

tedth66

458 posts in 1910 days


#2 posted 05-16-2012 03:46 AM

So far a great start Mark. Keep up the great work and I can’t wait to see the end result.

-- Ted

View mark76wa's profile

mark76wa

80 posts in 2116 days


#3 posted 05-20-2012 07:25 AM

I never have enough clamps. So I’ve got the boxes put together and attached to the base. I’m going to channel all the dust to the port with 1/4 ply inside the saw housing like I saw in a Wood Magazine article. I’m using a a 4” port and reducing it to my 2” hose that came with my dust collector. I will be adding a box to the left of saw once I get the saw in place.
I had a bit of an issue during the glue up. I glued it to the boxes to the top and put them together backwards. The 19” box should be on the left put I mixed it up because it was up-side-down. It still seems to all go together and will work. So I guess I’m … stuck … with it.
I will be making a blast gate for the main dust collection port when I get the router dust port figured out.
I’ll be painting it next. I think I’ll go with Red. My fav color. Plus, I thing it will go with Powermaic Yellow.

View zzzzdoc's profile

zzzzdoc

507 posts in 1724 days


#4 posted 05-20-2012 08:27 PM

Definitely keep the 4” port, as I fear the 2” won’t provide sufficient dust collection. On the other hand, you have it now, and it’s certainly better than no dust collection.

Nice job. Keep up the good work.

-- 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 1910 days


#5 posted 05-21-2012 10:27 AM

oh yah, it’s looking great Mark. With your “issue”, does that mean the router table will be on the right side?

-- Ted

View mark76wa's profile

mark76wa

80 posts in 2116 days


#6 posted 05-21-2012 03:00 PM

Ted,
I’ll just do all my routing upside down and backwards.

No, I still want the router on the left. I will flair to router box or something. Haven’t quite figured that part out.

It was recommended that I use an oil based enamel to paint it. I love the color but am betting brush lines and streaks all over the place. I wet sanded the first cost with 180 and put a second coat on but am still getting streaks. I only wanted to put 3 coats on it. Any suggestions?

Mark

View tedth66's profile

tedth66

458 posts in 1910 days


#7 posted 05-22-2012 10:38 AM

What about spraying on the final coat using Krylon enamel paint?

-- Ted

View mark76wa's profile

mark76wa

80 posts in 2116 days


#8 posted 05-23-2012 04:13 AM

I’m going to try one more coat without sanding. If that doesn’t I’ll wet sand and spray with Krylon. So very annoyed. I’ve been putting so much work into it and not having the best of luck. 1st my shopsmith doesn’t make square cuts. We, I’ll blame that on my saw not my craftsmanship. So there are some gaps as seen in the first pic. 2nd, my upside down and backwards glue up. That was all me. Now my paint is striking. Well I hope my new saw goes together correctly or I might have to get a new hobby.

View tedth66's profile

tedth66

458 posts in 1910 days


#9 posted 05-24-2012 03:11 AM

You’ll be fine Mark. I highly recommend spraying your final coat if a smooth finish is what you want.

-- Ted

View mark76wa's profile

mark76wa

80 posts in 2116 days


#10 posted 05-28-2012 06:00 AM

OK, so I ended up with two coats of brush on and one coat of spray. Wish I would have gone with another coat of spray but I got tired of painting. I really like how the colors go together.

I attached the saw to the base am working on mounting the motor.

I am having a problem with the belt rubbing. I’ve got the pulleys lined up and the belt is rubbing on the cover mounting bolts. I can’t move the bolts and an weary of fussing with my alignment but I’ve got to do something. Any Ideas?

I’ll post some more that better show how I channel the dust to the ports.

View SirFatty's profile

SirFatty

472 posts in 932 days


#11 posted 05-28-2012 12:07 PM

Good progress so far! Where did you get the casters?

-- Visit my blog at dave.spalla.com

View tedth66's profile

tedth66

458 posts in 1910 days


#12 posted 05-29-2012 03:36 AM

It looks as if you have the cover mounted in the wrong angle. It seems to me that the belt should straddle those mounts.

Ted

PS – nice paint job.

-- Ted

View mark76wa's profile

mark76wa

80 posts in 2116 days


#13 posted 05-29-2012 06:34 AM

The Casters are from Rockler.

The pic in the instructions has the two bolts in between the belt. I though about straddling it but it rubs too. I’m going to try realigning everything and see if that fixes it.

Mark

View mark76wa's profile

mark76wa

80 posts in 2116 days


#14 posted 06-04-2012 06:29 AM

Stage 2 complete!
I fixed the belt issue, then broke the belt by not paying attention. I found a 13/32” wide replacement that is a little bigger than the 3/8” stock belt. The red interlocking belt thing from Rockler was too wide for the pulley. It would seem that no one but Powermatic sells a 3/8×46.5” v-blet (for $25+s&h).

I’ve put together the rest of the saw. The colors look good together. All the wings and extension tables are lined, level and flat. I still need to align the fence and blade guard.
The left wing will be coming off in a bit so I can put together a box for a router. I want to add a work surface to the right of the right wing that extends past the tall box.
I’m thinking 10 or 11 drawers including the fake one where the dust collection ducting is. I need to think of what kink of slides I will use though cause some of them are quite pricey.

I think I’m going to figure out the best thing for dust collection next though since I don’t want to use the ShopSmith as a table saw any more!

View mark76wa's profile

mark76wa

80 posts in 2116 days


#15 posted 06-04-2012 06:42 AM

Oh, and on a flat surface the table top is 35 7/8” high. I have to figure out what happened to the other 1/8” ... Not.

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