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Porter Cable OSS 121 / down draft table in extension wing

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Project by Holbs posted 04-14-2017 03:59 AM 1202 views 0 times favorited 6 comments Add to Favorites Watch

I needed a final resting place for my PC121. I considered many options: keep it hand-held only, french cleat a little table against the wall, etc. But I knew since I dismantled my old bosch 4100/miter saw/down draft table mobile stand, I needed a new improved down draft table and sanding station for hand sanders (I still have to make a hardwood insert later). I looked around the shop and thought the right extension table for my Unisaw would make a great spot. I combined the PC121 and down draft table with the use of a 12”x6” Phenolic 0.625” thick sheet, rated at G-10. SUPER DUPER strong and stiff. Not knowing much about G-10 rated sheets, I went to town with my slightly used 3” Milwaukee hole saw. Well, see of yourself:

Ended up drill holes all around for the 2” spindle and sanding it out. Then, doing a rough calculation of 3/8” holes with my 3HP DC using 6” duct… around 800 holes seemed about right. Went through 2 new 3/8” Freud forstner bits. Apparently, laminated tops are not friendly to forstner bits :) Used a 1” hand chisel to flatten out the top after drilling the holes as some mushroomed upwards. I needed the bottom cavity to be removable in case I have to fully open my Unisaw right side motor cover and to tighten the extension wing bolts. Used some toggle clamps at the 4 corners along with window rubber seals along the top of the bottom cavity to seal it against the bottom of the extension wing. To level the Phenolic plate, I bought Kreg’s table insert levelers.
Did a quick test run of sanding a maple piece, whalla: no dust flying around. I could watch most of the dust get sucked downward and the bits that escaped didn’t go far.
So now my Delta Unisaw has my Benchdog cast iron router top, downdraft table, and OSS station. I’m a happy camper. But gotta figure better way for the PC121 power cord. Maybe always have it turned on and afix a switch outlet right at the end. For now…eh.

parts used:
Amazing Toggle Clamp GH-40323 Heavy Duty Hand Tool Quick Release Metal Holding Capacity Latch Type 360 Pounds
Kreg PRS3040 Precision Router Table Insert Plate Levelers
Frost King V27WA Extreme Rubber Weather-Strip Tape Cushioned Ribbed 1/2-Inch by 5/16-Inch by 10-Feet, White
Phenolic, Opaque Off-White, 0.625” Thickness, 6” Width, 12” Length

-- The Carpenter Bee is derived from the Ancient Greek word wood-cutter





6 comments so far

View Redoak49's profile

Redoak49

2906 posts in 1828 days


#1 posted 04-14-2017 10:58 AM

Very nice build and good way to control dust.

When I built my down draft table, I tried to have the area of the holes about the same cross section as the cross section of the duct.

View SuperCubber's profile

SuperCubber

1010 posts in 2124 days


#2 posted 04-14-2017 12:52 PM

Great idea, Holbs.

Is that melamine, or is it just the pictures making it look that way?

-- Joe | Spartanburg, SC | "To give anything less than your best is to sacrafice the gift." - Steve Prefontaine

View Holbs's profile

Holbs

1731 posts in 1869 days


#3 posted 04-14-2017 01:39 PM

Joe..that would be the original right side extension table flat & level laminated top, not melamine.

-- The Carpenter Bee is derived from the Ancient Greek word wood-cutter

View SuperCubber's profile

SuperCubber

1010 posts in 2124 days


#4 posted 04-19-2017 12:36 AM

Wow, looks can be deceiving!

-- Joe | Spartanburg, SC | "To give anything less than your best is to sacrafice the gift." - Steve Prefontaine

View Holbs's profile

Holbs

1731 posts in 1869 days


#5 posted 04-19-2017 12:39 AM

granted, unsure if “melamine” is considered laminate or not. I guess it would have to be. I just know melamine as the slippery rough surface I’ve seen at HD. With this being the original table, it’s smooth and slippery laminate.

-- The Carpenter Bee is derived from the Ancient Greek word wood-cutter

View SuperCubber's profile

SuperCubber

1010 posts in 2124 days


#6 posted 04-19-2017 01:26 AM

Nah, I understand what you’re saying. I was referring to the stuff you described.

-- Joe | Spartanburg, SC | "To give anything less than your best is to sacrafice the gift." - Steve Prefontaine

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