Help with table saw cabinet design

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Forum topic by Tony1212 posted 02-08-2016 04:34 PM 770 views 0 times favorited 1 reply Add to Favorites Watch
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180 posts in 1699 days

02-08-2016 04:34 PM

Topic tags/keywords: table saw cart router table cabinet carcass

This is a picture of my table saw/jointer cart as I got it from my grandfather. I have since replaced the original fence with a Vega Pro 40. It’s a bit hard to see, but he made it by welding up some angle iron.

This cart offers no storage or dust collection options, so I aim to fix that with cabinet/cart. I plan to build a platform with casters to roll it around my shop and build a cabinet for each component (jointer, table saw, drawers/cabinets. router) that would be glued and screwed to each other and the platform.

I was hoping to use 1/2” cabinet grade plywood from a BORG for the cabinet carcasses mainly to help save on weight (and saving on cost would be nice, too) since they would be glued and screwed together. Should 1/2” plywood work in this case or is it too flimsy and I should stick with 3/4”?

The total size of the cart would be 75” long (from the left edge of the jointer to the end of the fence rail) by 40” deep (from the front of the table saw to the back of the motor). The cabinets under the jointer and table saw would be 23” high and the drawer cabinet and router table would be 36”high. I would be removing the table saw wings seen in the picture.

-- Tony, SW Chicago Suburbs

1 reply so far

View JBrow's profile


1347 posts in 884 days

#1 posted 02-22-2016 01:37 AM


I would go with ¾” plywood for two reasons. First it is stronger. While I do not know how much maximum weight you expect the platform and cabinets to carry, it may be more than anticipated. I find myself using the table saw surface as a landing zone for lumber, which can get pretty heavy in short order.

Second, attaching drawer slides, whether wooden or roller slides, shelf pins, hangers, and hinges would be easier and more durable in ¾” plywood. Joinery is also stronger with thicker plywood.

Given the time and small additional expense invested in the project, I would go with ¾” plywood – plus the fact you are asking the question suggests you have your own doubts about ½” plywood. I have regretted building with other than ¾” plywood and I have never wished I had gone with thinner stock.

As to weight, if heavy duty casters with a high load rating per caster are used, moving the added weight of the plywood should not be too bad.

But if there will not be much weight carried by the platform or cabinets or there will be sufficient vertical panels to carry the load, ½” would probably work.

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