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.

Completed workbench:

>>>GET COMPLETE PLAN<<<

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 46 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

      1. Hey Jean,

        I too was curious about the electrical plans for this entire build. I understand life gets in the way, but I was curious if you had an update for this part of the project? Thanks for the great work all together!

        Parker

        1. Hey Parker

          Thanks for reaching out.
          Unfortunately, I haven’t gotten around to doing what I have planned but I will be sure to post it when I do.

  7. Will a notification be made available to subscribers when the downloadable plans become available? Or, better still, when is your next trip to Indiana, U.S.A? 🙂

  8. Hi Jean,
    Absolutely love your bench and explanations. You mentioned in your mitresaw video about possibly making a cover when it is rotated down but never explained it, then in the router installation video it is obviously in place. I noticed in the other comments that you plan to have a full set of plans in the new year – will this part be included?

    1. Hey Steve,

      There is a video on my channel where I explain closing the miter saw. Here it is if you haven’t checked it out. https://youtu.be/11mG6gc4bL0

      I am planning on including it in the plans yes.
      I hope to have an update with regards to the plans for everyone soon.

      Cheers
      Jean

  9. Fantastic work table Jean and thanks for the plans. It gives an amateur like me the confidence to have a crack.
    I have only just come across your channel and i think its great. Really looking forward to your home improvement videos in 2019.
    Great work Jean

  10. Hi Jean,

    I like your plan, so i am preparing to bulit .
    Are you able to use a mitter saw to cut 45 degree in a 600 mm slot?
    Thanks for answering!
    Best regards
    Jozsef

    1. I can with my saw but it won’t be possible with all makes and models.
      You will need to consider the saw that you will be using with your bench.

      Cheers

  11. Hey Jean,
    I really love this workstation! I am planning out my build right now. i can’t seem to find a place to sell me a whole sheet of MDF. Suppliers in my area only have 4×8 🙁 I wanted to ask you if you will be posting the rest of the build plans here? I’m sure you’re very busy, and I’m not trying to bug you, just wanted to know. Thanks again for this amazing idea!

    1. Hi

      I definitely will be posting the rest of the plans. I know they are way overdue but I have been a bit tied up between wedding planning, moving, my full-time job, and making videos.
      Thanks for understanding. I will try my best to start getting the info out again.

      1. Congrats on the wedding, moving, AND working full-time!
        Gosh have I been there before. My mom didn’t hear from me for like three months.

        For your miter saw recessed platform, do you have full functionality of the miter swivel?

        1. I do yes. In some of my more recent videos I make more 45° cuts. I did neglect to take the lock-knob into account but I have found an simple work-around.
          I would advise building the saw space 50mm wider however, just to be safe.

  12. Hi Jean,
    Awesome built so fare mate!!
    I can not find the plans for part 4 as yet.
    And any luck with the rest of the plans as yet?

    Regards

  13. I am not going to build this exactly, but the concept is spot on. I was looking for something modular, but I have a router table (a table top one) that would take a little adapting to your design. Still, great idea and great use of space!

  14. This is amazing, I would love to do something similar as my workshop consists of my 3rd car garage which my kids have taking over with most of their toys. Do you have all you plans on a single pdf. or similar that you would be willing to email?
    Beautiful work, I look forward to more videos.

    Cheers!
    Joe

    1. Hi Joe

      I will be making paid versions of the plans available soon as many people have requested such plans. These plans consist of roughly 100 pages and were redrawn on my behalf by a qualified mechanical engineer. I am simply waiting on some legal documents before making the plans live for $9.90. I hope this is acceptable.

      Cheers
      Jean

  15. Jean –
    Question for you. I just cut out my section from the worktop for my miter. I didn’t realize though that you installed a plank on the underside at the very back. Why did you do that?

    1. Hi Chris

      The plank had two functions. Firstly it was to stiffen up the top along the edge where I made the cutout. Also, you will notice if you watch the video again, that the cutout I made with the jigsaw was quite crude. Installing the plank on the underside allowed me to run my router with a flush trim bit along the plank to clean up the crudely cut edge. I did the same on the sides but could use the partition panels to guide the router.

      I used the same method when I made the cutout for the table saw and thickness planer.

      1. Oh ok. So your miter saw section essentially didn’t utilize the entire space you allocated to it on your 2D diagram? In other words the back plank takes up the “space” between your middle partition and the miter saw table?

          1. Awesome! Thanks. Totally understand now.
            One last question for today =) …..
            Nylon bushings. Necessary? If I have the set screw clamps on each end of the pipe, and the blocks are each drilled with a hole exactly the size of the pipe, why the bushings? I can’t understand what they actually do…?

          2. The blocks with a hole to match the pipe should work just fine also. I opted for the bushings as a way to minimize any potential wear from the pipe moving inside the pine block (with the added weight of the saw) over the long term.

Leave a Reply to Mykal Cancel reply

Your email address will not be published. Required fields are marked *