May 21, 2021

How to Build a Table Saw Workstation | With Video And A Free Plan

Want to Build a Table Saw Workstation? A workstation is an essential addition to any table saw. If you have one, you won’t be struggling with the tool more than you need to. If you don’t, you run the risk of injuring yourself when you use the table saw. A workstation gives your table saw a place to live. It also provides a place to put the necessary tools you need to use the saw safely. 

What You Need

Workbench

A workbench is a necessity when you want to build a table saw workstation. It keeps your accessories in one place. They are readily accessible for use. 

Measuring tape

The measuring tape is for measuring your workstation and material.

Oak hardwood and plywood

These are types of wood used as the base of the workstation. They are smooth, strong, and reliable. Since they have to be durable, oak wood takes the trophy between the two.

Circular saw

The circular saw has to fit into the workstation. The accurate dimensions of the saw make you know how much is going to fit into the table. 

Drill machine, screws, and board

Mini-sized screws build your table saw workstation. They secure and attach the stock. The drill machine helps you drill holes that accommodate screws and bolts in the attachment process. You get power from the mini-plug board. 

Jigsaw

A jigsaw cuts arches.

150-grit sandpaper

Sandpaper smoothens the material.

Glue

Wood glue attaches your stock.

How to Assemble Your Table Saw Workstation

  • Get the measurements
  • Cut accurate slots
  • Focus on side cutting
  • Attach the feet assembly
  • Outfeed the workstation
  • Drill the saw
  • Run the final touches adding a coating

How to Set Up a Table Saw Workstation

Choose the type of lumber and parts. As much as commercial plywood is accessible and affordable, I do not recommend it for your workstation. Hardwood materials are stronger and withstand construction than commercial-grade plywood. Hardwood lasts longer than softwood. For a start, you do not need cheap quality because it does not last long. In the end, cheap is going to cost more.

When you are satisfied with your lumber and parts, you have to start constructing your panels. Make sure you have 2 x 8 x 8inch boards for the setup. Use your plywood to construct your panels. There is a need for four types of plywood sheets for the sides and the ends of the saw panels. You have to sort out the saw panels before notches and saws. Make the top layer shorter than the table so you will not leave workpieces hanging. 

Cut the notches and make them accurate. The saw notches have to be interlocking and wider than the plywood. Wide saw notches are for structural integrity, easy setup, and easy dismantling. The saw notches have to be identical so that they line up perfectly. Make multiple cuts on every saw notch that is 1/8 inches of distance from one another. The chisel makes the cuts, and the sandpaper smoothens the saw notches.

Measure the size of your arches and take into consideration the size of the sides and panels. Trace the arches using the above sizes and cut them using a jigsaw. The arches are beautiful. You have to nail clears to the rear notches. Cut out the struts, notch them, and put the table back to its original position. Nail and glue your supports down. 

Make the table feet so that your workstation does not fall. Make use of leftover plywood to make the feet. The edges have to align. Nail and glue the feet to secure them to the table saw. Smoothen the corners, remove excess glue, and round the corners.

Place the strut support. The plywood top has to be nailed or glued for support. Measure the tables and make sure the outfeed table should not stick out under the sides and the front panels. Widen the notches using a file. 

Install a guide into the frame. That helps you know where you will be working on. Align the rail using clamps and align the fence. Make sure you align the blade before you finish fencing up. I advise you to use an adjustable bolt for ease and convenience.

Drill hanger holes into the trays using the hole saw. Round the edges using a router. Avoid splintering and sharp edges. Sand the plywood to smoothen your table saw. Coat the saw with polyurethane. 

Size your workstation

What determines the size of your workstation is your height. It has to be convenient and comfortable to use so that you do not strain your back. It has to allow you to make both long and short cuts as well as uniform cuts. Being comfortable using your table saw means safety. 

The correct height is the height that does not cause fatigue. Your table level has to be between the first and second thumb joints when the hand is at the sides of the user. Standard table saws range from 31 to 37 inches high.

If it means slighting a bit, that is still fine. If your table is too high, it is dangerous for you. You get off balance. 

Cut the wood to the size of your choice

  • Select a blade type
  • Set the fence
  • Set the angle
  • Set the blade height
  • Set the ripped board
  • Know the type of wood
  • Make precise cuts

Drill holes for bolts

Torque and speed

You have to dial the settings on drills for different applications. Some saws have speed control, and you are allowed to change from low to high. The hole drill has a wide range of settings.

Insert drill bits on the chuck. There is a ring of numbers that makes drills. Rotate the ring to choose the torque value of your hole drill. The torque stops the hole drill from spinning when it reaches a certain level of resistance. That helps you not to over tighten your screws and prevents snapping. 

Select your speed

The rotational speed is controllable on drills. The pressure applied to the trigger determines the blade speed. 

Types of drill bits

Helical drill bits are all-around, and they come in different sizes and lengths.

Spade is used for drilling larger diameter holes, and the point helps to keep it centered.

Hole saw drills larger holes that create a plug of waste material after cutting. Hole saws come in different sizes that range from 1/8 to ¼ inch. There is a hole saw size for multiple diameters. 

Prevent tearout using a piece of wood under the wood you are drilling a hole through. Hole saw removes the perimeter of your, and they create a plug when drilling. After hole drilling, there is a plug expected to be inside the hole. Removed the plug by inserting a screwdriver using one of the openings. A scrap piece drills an opening into the wood. 

Build a base for your table saw

There are factors to consider when building a base for your table saw. Mobility is a concern for the user. You stop the table saw from rolling even if it is mobile. The saw base should be able to withstand vibrations. 

That is why it has a durable and sturdy material. Screw swivel casters to a 2×4 inch that you have to attach to the legs of the table saw. Lock the machine in place and add feet to the base. Attach magnets to the feet and hold them out of the way. 

Safety Precautions

  • Do not wear gloves when operating a table saw. You lack tactical sense and gripping power.
  • Keep the environment clean from dust and cut-offs.
  • Wear proper eye and hearing protection.
  • Wear short sleeves so that your clothes do not have to meddle with your table saw.
  • Stay comfortable.
  • Use a push stick.
  • Use a stop block.
  • Your body has to be off the line with the blade.
  • Do not reach over the blade when the machine is still running. 
  • Disconnect power when changing blades.

Maintaining it

  • Keep the table smooth and polished.
  • Clean the sawdust inside the table saw.
  • Keep your gears lubricated.
  • Clean the blades.
  • Keep the anti-kickback pawl teeth sharp.

Video Tutorial

Free Plan

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Conclusion

A table saw is the most important piece of equipment in your workshop. You might be able to build fine furniture without one, but chances are you won’t be building anything at all without one. This is because you won’t be able to build anything that requires straight, angled, or circular cuts, unlike the work you can do without a table saw. I would love to see your fully built table saw workstation!  See our Radial Saw vs Table Saw comparison.

David D. Hughes
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