How to Build a Table Saw Workstation
Have you always wanted to have your own table saw, but couldn’t afford it or find enough room? Maybe you are not sure how to build a table saw workstation and how much time it would take you? Well, don’t worry, we’ve got you covered!
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In a few simple and easy to follow steps, we are going to show you how to build a knockdown table saw system. The advantage of this system is that you can quickly set it up and when you are finished, you can easily dismantle everything and have your space again. You can even hang your workstation on your wall.
Before you get started, we need to tell you that this DIY project will cost you about $150 and takes about one weekend to complete. The tools you will need include a drill, a circular saw, a jigsaw, sander, and of course the table saw itself.
As for the materials, you will need plywood, polyurethane, and sandpaper (150 grit).
How to Build a Table Saw Workstation: Step by Step
Step 1: Make the table parts
First, you need to make panels for your workstation. For this, you will need four plywood sheets. We recommend using hardwood plywood, made from oak.
Use separate sheets for side and the end panels. Use the same sheet to make the outfeed top and its end panel. From what is left, you can make the supports, struts, feet, and trays.
Step 2: Cutting notches—the most important step in building a table saw workstation
Now it’s time for the most important part of this project—the notches. When making them you have to be extremely accurate, because this table saw is based on interlocking notches.
To ensure easy setup and dismantle of your table saw make sure that the notches are 1/32” wider than the plywood. This will also make your table rigid.
Each notch should be exactly the same. The top of every part must line up, so you can have a work surface that is flat. Make several cuts for every notch, keeping 1/8” between cuts.
Finally, use a chisel to cut out the scraps of plywood. Smooth each notch with the file.
Step 3: Assembling the sides
Next, you need to do make the arches. Trace them on the back and front panels, and on the sides.
Once you have traced them cut them using a jigsaw. Side panels should have a 30” radius, while end panels should have a 24-1/2” radius. These arches will make your table saw look nicer, and be more compact.
To finish the side panels, nail and glue cleats over rear notches. Then, cut the struts and notch them so the outfeed table can be put into place.
Finally, nail and glue the supports to the struts. Do this on their inner sides.
Step 4: Making the feet
Time to make the table feet. Cut out the small parts from the plywood and then nail and glue them. Make sure that the edges are aligned and that they sit flat.
When you are done, use the belt sander or jigsaw to round over the outer corners.
Step 5: Finish and call it a day
After you are done making the feet, you can now place the strut support for the placement of the outfeed table. Take your plywood top and nail and glue it to these supports. This will make sure the struts are secured in their spot and that they won’t make trouble during the setup and dismantle.
The outfeed table shouldn’t stick above or under the table sides. Make sure that your front panel is also aligned with the table sides. In case that any notch is too tight, widen it using a file. On the other hand, if a notch is deeper than it should, use a glue to place a thin shim in the base.
Finally, drill holes to house trays and hanger holes so you can put away everything on a wall. For this drilling process use the hole saw.
If you want to make your table saw look nicer and to reduce the splintering on the edges, round over the parts edges with a router.
Finally, use the sandpaper on the plywood, vacuum it, and apply polyurethane over everything. Polyurethane will help with the warping when humidity changes. As a bonus, it makes everything look great.
All that is left is to install a saw on your workstation and you have yourself a table saw workstation. Well done!
This 5-step building process will help you to build your own table saw workstation. It is an affordable solution that will preserve your space.
Now, you don’t need to ask yourself how to build a table saw workstation. What you should be asking is, when do I start?