No Rust Table Saw Cover

  • Advertise with us
Project by CueballRosendaul posted 08-08-2012 01:58 PM 10998 views 23 times favorited 11 comments Add to Favorites Watch

If you’re like me, your table saw sees more action as an assembly and work table than it does actually slicing fiber and making dust. If your shop doubles as the family garage you may also have the problem of swings in temperature and humidity wreaking havoc on the pristine cast iron top. I keep the top cleaned and waxed but needed more protection so I built this 1/2” plywood cover with some oak rails on the sides to protect the cast iron top. I lined the bottom with ZeRust which is made to line drawers of your toolbox. It has a compound that off gasses for 5 years that coats things with a rust inhibitor. I applied spray adhesive to the bottom of the cover and stuck it to the bottom side of the cover board. The rubber texture keeps the top from moving around on me and the oak rails on the sides fit nicely over the edges of the work surface. The one mistake i made was not applying polyurethane to the bottom of the plywood before putting on the ZeRust and now it has a slight warp, but the oak side rails keep it to a minimum. I built a small one for my drill press also. The rest of the roll of material is lining toolbox drawers, my forstner bit box, and my hand plane storage.Seems to be working great for now, and i can set things on my saw without worrying about the top.

-- Matt CueBall Rosendaul. I don't think I've ever had a cup of coffee that didn't have cat hair or sawdust in it.

11 comments so far

View jaykaypur's profile


4017 posts in 2612 days

#1 posted 08-08-2012 02:28 PM

A great idea and a nice job too!

-- Use it up, Wear it out --------------- Make it do, Or do without!

View Woodwrecker's profile


4201 posts in 3779 days

#2 posted 08-08-2012 03:10 PM

Nice job Matt.
I’ve wanted to do the same thing.
I sweat like crazy in this hot weather and the cast iron sure doesn’t like that.
Plus, you get an extra work surface and who can’t use that/

Thanks for sharing your tips on the Z-rust inhibitor too.

View Benboy's profile


105 posts in 2465 days

#3 posted 08-08-2012 11:05 PM

What a great idea. Unfortunately I left a piece of freshly cut wood on my table saw for about a week. Might as well have set a wet sponge on it. now I am slowly buffing out a big brown rust stain… I can’t build one of these covers fast enough.

-- If I can't make it, I probably don't need it.

View Dusty56's profile


11822 posts in 3892 days

#4 posted 08-09-2012 01:02 AM

Nice project and thanks for the tip : )

-- I'm absolutely positive that I couldn't be more uncertain!

View scottb's profile


3648 posts in 4531 days

#5 posted 08-09-2012 02:49 AM

great idea!

-- I am always doing what I cannot do yet, in order to learn how to do it. - Van Gogh -- --

View BTKS's profile


1989 posts in 3668 days

#6 posted 08-09-2012 02:50 AM

I like this, looks like it’s more proactive than my sheets of 1in foam board. The humidity swings with temp changes are rough on shed shops!!! This may well become my TS, Jointer, Lathe and Drill Press protectors.
Thanks for the post.

-- "Man's ingenuity has outrun his intelligence" (Joseph Wood Krutch)

View kdc68's profile


2691 posts in 2480 days

#7 posted 08-09-2012 08:41 AM

Thanks for the great idea.

-- Measure "at least" twice and cut once

View CharlieM1958's profile


16281 posts in 4422 days

#8 posted 08-09-2012 01:12 PM

Why didn’t I think of that?!

-- Charlie M. "Woodworking - patience = firewood"

View Dave Dufour's profile

Dave Dufour

274 posts in 2182 days

#9 posted 02-04-2013 02:37 PM

great idea and a nice job

-- Dave, from Canada,

View JohnH2889's profile


14 posts in 2053 days

#10 posted 05-03-2013 01:31 PM

Hey Matt CueBall Rosendaul…How’s the Zerust lined table saw cover working? I have a new Steel City model 35990C table saw and would like to build a lined cover like yours, but I don’t know if the Zerust liner protects as advertised. I can be reached at

-- John H, Milwaukee, WI

View CueballRosendaul's profile


484 posts in 2344 days

#11 posted 05-03-2013 04:51 PM

Let me run down to the shop and I’ll look at the top very closely. Its been a wet and humid spring, in fact there was condensation running down the windows a couple weeks ago and it had me worried…....

There was a tiny bit of rust around the edges where the stuff doesn’t make contact. The table covers I built were 1/2 plywood and I made the mistake of not finishing the back sides, so they warped a little bit. If I was to do it over again, I think I’d use MDF and probably laminate the top like a countertop for easier cleanups. Because of my new fence, there is also about ½ inch that is exposed at one end. I usually cover it all the way, but that means taking the fence off my router table extension.

I’ll upload a one minute video through photobucket of the inspection I just did.

BTW I also put pieces of the same material in my router bit case, forstner bits, and hand plane box. and those are in perfect shape since they’re in closed boxes.

-- Matt CueBall Rosendaul. I don't think I've ever had a cup of coffee that didn't have cat hair or sawdust in it.

Have your say...

You must be signed in to post the comments.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics