Folding and Self-Locking Leg for Miter Saw Station

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Project by Wolfdrool posted 02-24-2016 04:54 PM 1313 views 6 times favorited 3 comments Add to Favorites Watch

This miter station is only half built, but it is already proving to be quite useful. My favorite feature is this folding, self-locking, leg design.

With two hinged joints and no other hardware, the leg is a floppy noodle until you deploy it. Then it becomes very rigid and strong. The stability and strength of the leg is quite surprising. Once it is deployed, you can even knock the leg in the side and it will stay rigid. A key to this stability is the way the hip box pivots from an inside hinge while supporting the top outside the hinge. This creates forces that prevent the leg from folding unless you lift the table and the leg off the ground far enough for the hip box to pivot down.

Not shown in these pictures are the fences, dog holes, flip stops, further extension tables that slidably mount to the folding wings when deployed up, and in-progress folding dust control system. The sliding extension tables use ½ inch emt rails and offer up to 9 MORE feet (as shown, the saw has 70 inches of support to either side of the blade) of support right or left when needed. I tend to use 3-foot emt mostly for these, which allows stops out to 100 inches from the blade as needed.

This station is based on the design in ShopNotes No. 31 with a few changes. The main cabinet is taller and wider. The shelves are torsion boxes for strength due to the extra width. One problem with the original design is that the saw is not very useable when the wings are folded down. I added mini-wings that are always deployed so the saw is useable all the time. The mini wings provide 31 inches of support to each side of the blade. With the far end of the folding tables being so far out from the main cabinet, I also needed a better support strategy out at the ends so the saw station won’t tip side to side under load. The folding legs do this job well. I also added the sliding auxiliary tables.

3 comments so far

View trevor7428's profile


130 posts in 385 days

#1 posted 02-24-2016 10:40 PM

Looks great, but why is the saw not usable if wings are down?
Are you planing to use the kreg fence system. I found it extremely useful.
Also what are the dog holes for? Can’t think of a use on a miter saw

-- Thank You Trevor OBrion

View Wolfdrool's profile


50 posts in 2821 days

#2 posted 02-24-2016 11:16 PM

Trevor: When the wings are down on the standard design, only the saw table supports the workpiece. This is not a lot of support for even doing simple things like trimming the end of long boards to snake up on a good fit without boards sagging, etc. The mini tables provide plenty of support for this and lots of different saw operations where a stop block is not needed.

I built fences for the saw. One of them is shown with the flip stop that I posted earlier today on Lumberjocks. The Kreg fence is better, for sure, but this one is more cost effective. For me, the Kreg fence is on the dream list rather than the reality list. I need to add measuring tapes, still, to the fences I built.

Dog holes have a lot of uses. For one, the tables when up provide great work surfaces in there own right. So, the holes are used on these tables just like you would use them on a workbench. Also, I have hold down clamps that fit into the holes to help hold workpieces, or stacks of workpieces, in place against the fence. The holes also provide very useful backstops for pieces when using a biscuit joiner to cut biscuit slots. I also have jigs that fit into these to help assemble cabinet parts in alignment and square. These are great sanding tables, too, and the dog holes help with that, too.

View dougsshop's profile


49 posts in 252 days

#3 posted 02-25-2016 12:22 AM

I like it! Good equipment set-ups make the task alot easier.

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