NO CLASH! Miter Saw Installed To Table Saw Outfeed Table | All-In-One Workbench PART 3

Making the most of a small shop – Part 3

In PART 1 and PART 2 of this, The Ultimate All-In-One Woodworking Bench build, I assembled the frame and with some clever techniques, installed my table saw to sit perfectly flush with the top. However, simply installing a table saw to a woodworking workstation does not make it the “ultimate”. That’s why I jumped right back in and added my second tool to the bench.

 

With PART 2 complete, the table saw was installed.

 

After my table saw, my miter saw is one of the most crucial pieces of hardware in my shop and therefore it was to be the next tool to be added to my All-In-One woodworking station.

No Clash! Miter and table saw on one workstation

With my Makita MLT 100 table saw installed I was able to use the entire 2.4m(7.8ft)X1.6m(5.3ft) bench top as an outfeed table. This greatly increased the usability of this nifty little table saw.
The trick now would be to install the miter saw in a way that would still allow me to use the entire bench to support overhang when sizing panels with the table saw.
I also wanted to recess the miter saw so that the bed on the saw would sit flush with the top of the bench.

To do this I decided to install a recessed bed with a pivot at the back for my Metabo KGS 254 M miter saw that would allow me to fold it away underneath the bench when it restricts the cutting of large panels with the table saw.

 

Note: Because not all miter saws have the same dimension this design may need to be adapted to accommodate a different saw.

PART 3: Table saw miter saw combo workbench

The instructions that follow are intended to be considered along with the visual instruction provided by the video above.

Planned layout when completed.

Step 1: Top Cutout

My first step in adding my miter saw to the workstation was to remove the segment of the bench top where the miter saw would be installed.

To make this cut-out, a guide plank was installed on the underside of the bench top at a depth that would adequately accommodate the miter saw. In this case, 700mm(27.559″).
To determine this distance I considered the length of the saw (back to front) with the slide in its forward position.

I used this plank along with the two partitioning panels that form the sides of the miter cavity to guide my cut.
By cutting slightly toward the inside of the guide plank and these panels, I removed the largest part of the cut-out using a jigsaw. The remaining edge was trimmed using a router and a flush trim bit.

The two partitioning panels that form the sides of the box was installed at a width that would accommodate the miter saw bed at a 45° angle in both directions (PART 1).


Step 2: Miter saw base preparation

With the cavity prepared, I assembled the base to which the miter saw would be fixed.

The base was assembled with stiffener planks on the underside to prevent deflection.
The pipe holders that would form the pivot point was attached to these stiffener planks toward the back of the base.

For the hinge action, I used a 19mm(3/4″) stainless steel pipe which meant that the pipe holders needed a 19mm(3/4″) hole drilled in the center to accommodate the pipe.

Further preparation on the saw base was done by cutting holes on the two front corners to accommodate the latches that will be used to lock the saw base in its working position.


Step 3: Fitting the base to the bench

To add the prepared miter saw base to the bench, holes needed to be added to the cavity side panels that would allow me to extend the pipe through on both sides.

These holes were made to be oversized, allowing the pipe to sit loosely inside them. I could then install bushes on the outside of the side panels in a way that would allow me to slightly adjust the height of the base.

Step 4: Bush and bush housing preparation

The bush housing was cut from a piece of pine plywood.

A hole was drilled in the center of the bush housing into which the bush would be inserted.
Further preparation of the bush housing was done by adding four slots to be used to fix the housing to the side panels that form the cavity.
The slots were made by drilling two holes per slot and removing the piece between them with a jigsaw.
Adding slots to the bush housing is what would give me the ability to fine-tune the height of the saw.

The bush was made from nylon as it would be more resistant to wear when the stainless steel pipe rotates inside it.
In addition to the this, a flange with four holes was added to the bush so it could be fixed to the housing with screws.

Step 5: Fixing the bush housing and latches

With the bush housings prepared, installing them was as simple as sliding them over the pipe and attaching them with bolts from the inside of the miter saw cavity.

The bolts were sunken to prevent them from clashing with the saw base when it is being folded up/down.

After the bush housings were fixed, a clamp was added to the piece of pipe protruding from each bush to prevent the pipe from moving out of the bush.

At this stage, the base was clamped in its working position and the miter saw attached to it. This allowed me to make fine adjustments to the bush housing to line up the bed of the miter saw with the bench top.

Thereafter, toward the front of the cavity, in line with the holes cut in the base for the latches, stop blocks were installed on both sides.
The toggle latches were installed on top of the stop blocks allowing them to latch the base in place through the holes.

Part 3 Finished!

Part 3 of my All-In-One bench build was concluded with the bush housing secured and the front toggle latches installed.

Now I would be able to disengage the toggle latches and swing the whole saw down and out of the way of the table saw when needed.

Clips were added to the latches to prevent them from popping open while the saw is being used.

I am still planning on adding additional failsafe mechanisms to prevent the saw from dropping in the case of a latch failure. This will be explained as the bench build continues.

 

Posted by Jean

Website: http://woodworkjunkie.com

This article has 18 Comments

  1. Am not sure if I’m missing anything in your build? So far, I’ve seen the construction of the bench, the table saw and mitre saw stations and the compressor.. Am I missing anything?

    Regards
    Mark

  2. Jean,

    I have been wanting to do this build for a long time. I never thought of the pivoting mounting tables for the miter saw or the planer. Amazing ideas and designs. Is their still a way to clamp stops on your miter saw to so multiple cuts of the same length? If not that would be a great add on. Cheers mate and can’t wait for the next video.

    1. Hey Ric,

      The fence I’m adding for the router table (the last installation) will double as a fence for the miter saw. To this fence, I will add an adjustable mechanism that will allow you to make repeatable quick cuts with the miter saw.

      The next video is the dust collector and I’m currently working on finishing it up.
      After that, I’m tackling the router table.

      Cheers
      Jean

  3. I really want to make one of this, may I know where you get your nylon bush and the clamp lock for the bar?

    Many thanks

    1. Hey there Patrick,

      The bush and the clamp I made myself.

      I included the bush dimensions so that it can be mimicked by anyone with a bit of turning skill. If this is not an option you can swap the bush out with bearings.
      As for the clamp, unfortunately, I did not add the dimensions for it but a simple cotter pin will yield the same results.

      Jean

  4. I thank you for your efforts on this project . I have copied the first 4 parts but at this time I can not locate part 5 -7. Not to push, but have you completed the plans for the entire project yet? If so where can I fine the missing links?Just a couple of comments regarding the use of PVC in dust collection. 1. how do you deal with static electricity build up? dust and static electricity is not a good combination. 2. I understand that 90 degree angles can reduce the amount of suction power in the system. Instead of 90 degrees a pair of S curves serve the same purpose with less reduction in power. What are your thoughts? Please continue doing the good work you have been doing on these projects.

    Thanks you for your consideration.;

    1. Hey Ken

      Firstly, very sorry about the delay in the plans. Besides the fact that I was already behind with the plans, I had some computer issues recently and could not access some of my files. I have recently gotten the repaired computer back and have jumped back in. I hope to start putting up the next parts within the next two weeks.

      As for the dust collector system, I must admit, mistakes were made on my part. I’ve never built a system like the one I built for my bench before. I am currently working on rectifying some of these mistakes so stay tuned.

      Cheers
      Jean

    1. Hi Manual

      I assume you mean the rail extension for the table saw fence?
      There is a brief description in this video: https://youtu.be/Eu8owh6d9RU

      The video is the one where I explain adding my table saw to the station. In the video, I show and briefly explain the rail extension.

      Feel free to ask if you need more info.

      Jean

  5. Hi I am in the USA can you convert the measurements to imperial instead of metric. I am trying to build one but can’t follow your measurements I know I will have to change some measurements for my tools. Congratulations on your project it is great. Thanks

    1. Hey Chester,

      The measurements are already converted to imperial. The units in the brackets [] are inches. The decimal is expressed in a thousandth of an inch.

      Cheers
      Jean

  6. Have you created downloadable and printable plans for your All-In-One Woodworking Table Miter Saw Station? If so, where can I find them and what is the cost? I am very impressed with your project and may want to replicate it in my small shop.

    1. Hi Kevin,

      I am working on very detailed plans that I am planning on making available to people that would like to build their own versions of the bench. Unfortunately, it will only be available in a couple of months.

      Cheers
      Jean

    1. Hey Jon,

      I’m hoping to make detailed plans with dimension together with all relevant info like electrical diagrams available early in the new year.

      Jean

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