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Sawstop and Router Cabinet / Infeed Table / Outfeed Table Project

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Blog entry by zzzzdoc posted 10-19-2010 12:56 AM 21091 reads 69 times favorited 462 comments Add to Favorites Watch

At the very start, let me give all the credit in the world to Tedth66, whose project this is totally based on, and who has been graciously providing guidance as I build this. This is a modification of his design, adding a few details, and making it work for my shop.

I have a 2 car garage / workshop that is tremendously space challenged, so I need to be clever about every square inch. On top of that, I enjoy modifying designs and making them work custom for me. So when I saw Ted’s great SawStop Cabinet and Router Table, I knew I had to build it. Additionally, I just had to have better dust collection than the SawStop contractors saw provides. This design should dramatically improve that. I plan on 5” for under the table saw, with 2.5” for the above table guard, and 6” to the router table via a separate drop.

For reference, here’s Ted’s completed project:
My SawStop and Router Cabinet project

I’ve been spending the past few weeks slowly building this component-by-component. First the mobile base. I beefed up the original design by adding two more casters (total of 6 now), as with the additional components, the weight of this will be substantial. This design (a torsion box with 3/4” plywood) should be able to handle 900 lbs.

Here’s the completed base (plans are available from Woodstore—It’s their Mobile Sawing/Routing Center):

I was concerned that the countersunk holes for the bolts would weaken the frame, so I filled them with West Systems 3 Epoxy with high-strength filler. I think the resultant areas should be at least as strong as the original oak plywood.

The completed center will have a cabinet for the SawStop, drawer storage for saw blades, wrenches, jigs, guards), a cast iron router table with Incra Fence and integrated dust collection, a swivel down outfeed table (taken from the February 2009 Woodworker’s Journal – which I think is the neatest one I’ve seen), and, if I can make it work, a maple workbench top with vises. It’s a tall order, but I’d like to see it through.

Well, more building to do, but wanted to get the blog rolling. Please feel free to add comments / suggestions / criticisms / etc.

-- Before you criticize someone, you should walk a mile in their shoes. That way, when you criticize them, you're a mile away and you have their shoes.



462 comments so far

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zzzzdoc

506 posts in 1654 days


#1 posted 10-19-2010 12:59 AM

The top is being glued to the airbox. I have routed out the openings for the SawStop Contractor’s Saw. Next step will be to install the drawer slides, and build the second box. Then I’ll glue both boxes to the base.

-- Before you criticize someone, you should walk a mile in their shoes. That way, when you criticize them, you're a mile away and you have their shoes.

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tedth66

458 posts in 1841 days


#2 posted 10-19-2010 05:21 AM

Wow!!! I really like what you’ve done so far zzzzdoc. It’s looking GREAT and this is bringing back memories of when I was building my cabinet for my saw. I can’t wait to see future pictures as you add your boxes to your base…. NICE WORK!! I can tell you take pride in your work.

I see a Festool track in the background… do you have the TS55 like I do? I love my Festool saw.

-- Ted

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zzzzdoc

506 posts in 1654 days


#3 posted 10-19-2010 05:42 AM

Yes, in fact much of this was done on the Festool TS55. I never like hauling sheet goods over a table saw, so I’m doing more and more with the Festool. Getting square and parallel edges has been a bit of an issue, though. I’ve found that if they are a little oversized, a little trimming with a pattern bearing bit does wonders.

I did the routing with the Festool track, Festool OP 1400 +/- pattern bits. I still think routing the opening was the hardest step thus far.

It’s amazing how many steps this build involves. I’m not going to ask how long you took. It would be too depressing.

-- Before you criticize someone, you should walk a mile in their shoes. That way, when you criticize them, you're a mile away and you have their shoes.

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zzzzdoc

506 posts in 1654 days


#4 posted 10-24-2010 11:22 PM

Built the second box with the SawStop instead of the Festool. Went much quicker and straighter.

Drawer slides are installed. I’ll build the drawers later. Easier to set up the PC jig and knock those all off at the same time.

-- Before you criticize someone, you should walk a mile in their shoes. That way, when you criticize them, you're a mile away and you have their shoes.

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tedth66

458 posts in 1841 days


#5 posted 10-25-2010 03:07 AM

WOW,,,, it’s looking real good Alan. Outstanding job. I just sent you the dimensions for the accessory pullout shelf.

-- Ted

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zzzzdoc

506 posts in 1654 days


#6 posted 10-25-2010 03:54 AM

Thanks. The second box was easy. Now they start getting challenging again. I can see it will be great to be able to store blades, wrenches, and especially the guards / riving knives in a convenient spot.

I can see that installing slides in an 8” wide box could be a pain. Much better installing them before gluing up the case.

-- Before you criticize someone, you should walk a mile in their shoes. That way, when you criticize them, you're a mile away and you have their shoes.

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tedth66

458 posts in 1841 days


#7 posted 10-25-2010 10:57 PM

BTW Alan, my pull out shelf does not touch the under side of the SawStop extension table. The right side of my saw is attached to the router box which is attached to the box that houses the two drawers under the router table.

The router table was really challenging for me as getting the height correct was a pain in the you know what.

-- Ted

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zzzzdoc

506 posts in 1654 days


#8 posted 10-25-2010 11:54 PM

Interesting.

At what stage did you take the saw off it’s base and place it onto the new cabinet base? The extension table on the right has that monopole support, which I assume gets in the way of the router table.

I really need to be able to use the router table as my sole router table, so I’ll probably have to attack the rails to make room for the miter slot. Boy, didn’t see that one coming.

-- Before you criticize someone, you should walk a mile in their shoes. That way, when you criticize them, you're a mile away and you have their shoes.

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tedth66

458 posts in 1841 days


#9 posted 10-26-2010 05:56 AM

I’m not sure as I must have made 3-5 test fits and then when I was done building the cabinet I used it for a while and then decided to paint the cabinet so off came the saw for the final time.

I ditched the extension legs and made a new extension table with a slightly thicker top. The SS extension table was a 5/8ths piece of MDO. I used a 3/4 inch MDF and laminated it.

-- Ted

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zzzzdoc

506 posts in 1654 days


#10 posted 10-26-2010 06:04 AM

Wow. I figure I’ll have one good shot to get friends to come over and lift the SS. I don’t think 3-5 test fits will be in my future.

I do have a overhead hoist which I might use which can easily lift it, if I can find good places to screw in bolts to use for lifting.

-- Before you criticize someone, you should walk a mile in their shoes. That way, when you criticize them, you're a mile away and you have their shoes.

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tedth66

458 posts in 1841 days


#11 posted 10-26-2010 11:18 PM

I actually took the saw apart each time,,, what a pain but in the end it was worth it.

My router box was a pain because i didn’t want that hose sticking out the back so I designed my table to pull the dust down through the table and created a router box fence to channel it down that port. I think you can see the ported hole in the top of the table. In the end, it works great but it was a lot of extra work to get it in there.

-- Ted

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zzzzdoc

506 posts in 1654 days


#12 posted 10-26-2010 11:53 PM

Ted:

I’m going to have to glue/screw up all except the router boxes, then fit the saw and leave it there. The router box will come last and go under the table. Don’t see how else I’d be able to do it, with a definite lack of helpers around here.

I’m just about done with the box for the guards, blades, manuals. Just need to glue up the drawer and it’s done.

Let me jump to the next step. Can I get some dimensions for the router box?

-- Before you criticize someone, you should walk a mile in their shoes. That way, when you criticize them, you're a mile away and you have their shoes.

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tedth66

458 posts in 1841 days


#13 posted 10-28-2010 11:59 AM

hey Alan,

That will work because the right side extension table is removable so you can easily access the router portion of the box.

I’ll get you measurements tonight ,,, this one is tricky and you might want to go with your own measurements on the router box. The thing is, what you see in my pictures is deceiving as the router box isn’t as big as you think. The walls on the left and right are not part of the router box.

check this link out,,,,
http://lumberjocks.com/tedth66/blog/13875

-- Ted

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zzzzdoc

506 posts in 1654 days


#14 posted 10-29-2010 05:21 AM

OK. the guard/blade box is finished. Router box next. Now things get complicated again.

-- Before you criticize someone, you should walk a mile in their shoes. That way, when you criticize them, you're a mile away and you have their shoes.

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tedth66

458 posts in 1841 days


#15 posted 10-29-2010 02:49 PM

Looks GREAT Alan. Are you going to add a couple of 5/8th inch dowels for your blades or do you have something else in mind? If you go with the dowels you might have to have them positioned a bit differently than I do since your left side is taller than my left side. This cabinet is looking rock solid.

Did you get a chance to look at my router box link above? Do you want me to still get you measurements or are you going to change it up? Really with the false walls on the left and right of my router box the box that you see in the link can be any size you want. I recommend small so the dust collection is efficient. The box below the router box is simple ,, you’ve already established the width; just remember to account for the lip that you’re leaving for the boxes (with drawer fronts) under the saw. I have a half inch lip all around the front, left and right of the cabinet. The height of the box that sits under the router box is tricky as this is whatever is left over after you define your router box height. Should I at least get you that measurement?

Ted

-- Ted

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