How to Build Table Saw Workstation

This is the pinnacle of table saw advancements! Not only does it add a massive work area to your bench top or contractor style saw, but it can also be used in conjunction with some of our other homemade tools to create an entire workshop in a 4X8 foot space! It can be used alone or in conjunction with our Sliding Crosscut Table, T-Track Downdraft Table, Sliding Router Table, Homemade TS Fence, and Jig Saw.

Additionally, sixteen drawers, several storage shelves, and space for a variety of other small machines are included. Add a bench top drill press and a mini lathe, and the possibilities are endless! This is an extremely well-planned project that is well worth the price of the plans! (There’s even a built-in lumber rack!)

Procedure to Make a Table Saw Workstation

Construct the Panels

If you’re building this workstation for a saw that comes with its own cart, you’ll need to take some measurements first. You’ll need the height of the saw from top to bottom. Now subtract three-by-sixteen inches from that figure to get the measurement for the side panels. Now subtract three and a quarter inches from that figure to get the measurement for the front panels.

Cut Accurate Slots!

Ideally, you should have 2′′ x 8 x 8′ boards for your workstation. Using your chosen plywood, begin panel construction by preparing four different plywood sheets for the workstation’s sides and the panels’ ends. This step must come first; the panels are necessary for the workstation before you dive into notches and saws.

Arches and Assembly

Accurate slots are required for the interlocking notches. Keep the notch 1/32 inch wider than the plywood to ensure greater sturdiness and ease of setup. All notch depths should be the same. This is necessary for aligning the tops of all parts. Otherwise, your work surface will be too uneven to work on.

Focus on Side Cutting!

Estimate or measure the size of your proposed arches, taking into account the sides and panels. Trace the arches there, then cut them out with the jigsaw! Arches are not only strong, but also visually appealing, and they can help make your table more compact.

Time for Feet Assembly

Nail a wood strip into a scrap of plywood for this step. Now, trace and cut arches at the bottom of the side and end panels, keeping the cutting ratio correct. Use a jigsaw for this step. Adding such a curve will make the workstation lighter, as well as provide a better appearance and ease of handling. Make cleats for the table feet over the back notches. For the out feed table, simply cut and notch struts. Glue and nail any supportable part inside the struts. Your workstation must be supported; you cannot have it fall over! Use leftover plywood to cut out small parts for the table feet. Once again, accuracy is critical; all edges must align precisely; after all, you want your projects to sit flat! Nail and glue them to ensure they do not collapse. Sand and smooth the corners, remove excess glue, and round the corners.

Place Support

You’ll need to cut tiny plywood pieces for the feet and attach them with glue and screws. Don’t forget to check the edge alignments and that the table is sitting flat. Round the pure corners gradually with a belt sander or jigsaw. There should be no oozing glue remaining.

Out feed of the Workstation

After the feet, install the strut support. This is necessary for the placement of the out feed table. The plywood top should be nailed or glued to the supports! You don’t want any mess when setting up and dismantling your workstation.

While laying struts for the out feed part, keep the feet supporting the sides, front, and rear panels.

Out feed of the Workstation

Once the struts are properly positioned and do not bind or cause any knockdown incidents, it’s time to glue the supports to the top.

Examine the interlocking joints. Are they all the same height? Are the sides and front panels flush? If not, use a file to remove any tight notch. You can also remove any excess depth using a thin shim.

Go for Fences

It is not strictly necessary, but having fences may be critical later on. Purchase some metal or look into steel as a substitute. Install a guide into the frame to indicate where you can work on the supporting brackets. Align the rail with clamps, then the fence. Check the blade alignment before finishing the fence.

Drill It Out!

Now, using a drill, drill some holes for hanging parts. You can go with 2.5-inch holes on each side and a 16-inch hole in the center for wall stud alignments. Also, drill a half-inch lag screw into studs.

Drill with a whole saw, starting from one side and continuing until the pilot emerges through the opposite side. Return to the opposite side and drill again to complete the hole.

The Final Touch!

You can take a break here or continue installing the saw into the workstation immediately. Congratulations! You’ve created your own table saw workstation. It’s less expensive, more customized to your needs, and comes with quality assurance. Test it out for yourself; if you notice any flaws, you’ll know which process produced them and can quickly rectify the situation.

Conclusion

You now have a lovely and convenient workstation for your precious table saw; with proper maintenance, it should last you for many years. If you believe your projects are more professional in nature and require additional effort, I believe purchasing a specialized workstation would be prudent. However, there is nothing wrong with saving money on minor woodworking projects.

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