|Project by BrockF||posted 11-16-2014 03:11 AM||3346 views||5 times favorited||5 comments|
I began this in February and completed the initial project in November. My vision of the new shop was to maximize storage space while minimizing the footprint of machines and shop fixtures. A bench that incorporates the table saw would do this but this significantly raised the complexity of the project. I also needed to work things out so that the bench was easily mobile, my ideal working height, and incredibly strong. The main portion of the frame is 2×10 Douglas Fur, triple glue laminated with 2×4’s and reinforced with heavy duty SPAX construction lags. To provide total resistance to racking a series of tortion boxes makes up the internal structure. Each of those is made of 2×4’s and glue laminated/screwed 1/2 inch plywood. I used the kreg jig throughout as well. All the upper structure is also glue laminated 2×4’s. The table saw weighs 400 pounds and sits on heavy duty framing and 3/4 baltic birch. The bench rolls on six steel wheels and incorporates 5 large shop built leg levelers. Each is a series of glue laminated blocks of oak mortised to accept 3 1/2 inch square nuts. In these rides a 1/2 inch threaded steel rod with a counterbored hockey puck foot. Each leveler has a nut secured on top with high strength JB Weld so it can adjusted from above with only a rachet. Good for those with bad backs. I made the rods long enough to act like jacks and it makes the bench rock solid. Also very handy for perfect height adjustment. Each leveler is heavily bolted and or lagged to the bench frame. The design is my own. I could not find any other leveler design that came close to serving my needs. I ran pvc pipe under the bench for dust collection to the saw. The saw came with a plastic dust chute with a 4 inch outlet but its cheap and badly designed so I ditched it for my own upgrade. I have a 16 gallon craftsmen wet/dry vac that I can hook to a rear dust port on the bench. If I ever get a dedicated dust collection system I will have to make modifications but for now it works rather well. I had considered installing a few outlets but the existing outlets in my garage shop are close enough that I decided to not complicate things. The benchtop and drawers will have to wait for next spring as the temperature has dropped well below glue up conditions. The trim will come too and i will paint it white. A little patriotic flair and the I can call it the Victory Bench.