June 6, 2021
A table saw workstation is easier than you think. As woodworkers, it’s almost impossible to work without a workbench. You want your tools and projects all in one place!
And then, you take a peek at the prices. If you don’t have a budget and feel like you can take a DIY project on, this table saw workstation guide is for you.
Most woodworkers buy their own workstations, but in reality, nothing stops you from making your own. You don’t even have to shell out thousands of dollars. Once you have the essential tools, time, and effort, you can create a minimal workbench by yourself!
No experience is required, either. Even if you’re a beginner, we’re sure you can pull this off. You don’t need fancy equipment or a certification. Follow the instructions, and we’re sure you’ll like the results.
Are you curious to know how to build a table saw workstation at home? We have everything you need to know in this article. Stick with us for this project until the end, and you’ll have your table saw workstation soon!
Materials & Tools You Will Need:
Before we jump into the step-by-step process, you need to equip yourself with the proper tools first. There are multiple table saw workstation plans, so make sure you know what you’re trying to achieve before anything else.
Don’t worry about the materials you need. Every one of these tools is easy to find if they’re not in your possession already. Make your workstation a success with the following tools:
- Oak hardwood
- Circular saw
- Drill machine
- Mini-sized screws
- Multi-plug board
- 150-grit sandpaper
- Wood glue
- Measuring tape
Wait, what’s all this for?
First, the oak hardwood and plywood will be the base of your workstation. You need something strong, durable, and long-lasting. Oak-made wood is the best pick for those purposes!
A circular saw must fit into the workstation. While you’re at it, get the saw’s dimensions. You want to know how much can fit into the table. See how the jigsaw will fit, too.
A drilling machine, screws, and plugboard are some essentials. You need power and hooks. Keep those three in mind when you get to that process.
How To Build A Table Saw Workstation in 9 Easy Steps
You don’t have to feel around in the dark trying to get to know a store-bought workstation. Instead, you see the setup, organization, and flaws of your own workspace! Nothing beats the ease and convenience a home-built workstation gives.
Are you ready to dive into the step-by-step process? Let’s begin.
Step 1: Choose The Right Type of Lumber & Parts
Commercial-grade plywood may tempt you, but it’s a no-go. For its price, you’re getting something cheap and prone to warping! They’re difficult to clean, as well.
In the end, you might end up scrapping the entire workstation to get new materials. It’s going to degrade and decay, leaving you with a waste of time, money, and effort. While commercial-grade plywood is more accessible, go out of your way to look for suitable plywood.
Hardwood materials are your best bet. Go for oak! They’re strong and can withstand construction. Plus, you’ll find that they last much longer in comparison to commercial-grade wood. It’s not advisable to go for soft plywood, so steer away from that option. It will sink too quickly.
Remember: you want durability. Start off strong, and the rest of your workstation will be a success.
Step 2: Construct the Panels
Ideally, you should have 2″ × 8 × 8′ boards for your workstation.
With your chosen plywood, you can start panel construction. Prepare four different plywood sheets for the workstations’ sides and the panels’ ends.
This step must come before anything else. The panels are a must for the workstation before you jump into notches and saws. That’s why we have plywood on our table for the materials we will need. Make the top layer shorter than the table so workpieces won’t be left hanging!
Step 3: Cut Notches
Are you done with the panels? The workstation relies on interlocking notches. Cutting notches is a crucial part of the project, so do this step with care! You want your notches as accurate as possible.
Your notches should be a bit wider than the plywood for structural integrity, easy setup, and hassle-free dismantling. Don’t make it any harder for your future self.
Individualism is not a thing for these notches. Instead, every notch must be the same. While we can’t guarantee perfectly identical pieces, try to make them look like they are! You want everything to line up, so you have a flat work surface. For every notch, make several cuts at around 1/8 inches of distance from one another.
A chisel comes in handy when you want to cut out plywood scraps. Then, smooth down notches with sandpaper or a file.
Step 4: Arches and Assembly
Estimate or measure out the size of your proposed arches. The sides and panels should be factored in when you take measurements. Trace the arches there, then cut them out using the jigsaw!
Beyond strength, arches are visually appealing. You can also make your table more compact. By the time you get to this step, you should nail clears to the rear notches. Cut out struts, notch them, then put the outfeed table back to its place.
You can’t go anywhere without ample support. The inner sides of the table should support the rest of the workstation. Nail and glue your supports down!
Step 5: Make the Table Feet
Your workstation should stand on something. You can’t have it falling over! Use leftover plywood to cut out small parts for the table feet. Once again, accuracy is vital. All edges must align. After all, you want your projects to sit flat!
Nail and glue them to make sure they won’t collapse. Sand and smoothen the corners, remove excess glue, and round out the corners.
Step 6: Place Support
After the feet, place strut support. You need it for the placement of the outfeed table. The plywood top should be nailed or glued to the supports! You don’t want any mess to happen when you’re setting up and dismantling your workstation.
Measure the tables you have. The outfeed table shouldn’t stick out under the sides, and the same goes for the front panels. Make sure everything is aligned! It’s for your safety, too.
Widen tight notches by using a file. Deep notches can benefit from a thin shim glued to its base. Everything should be in balance.
Step 7: Go for Fences
It’s not strictly required, but having fences might be crucial later on. Purchase some metal or look into steel as a substitute. Install a guide into the frame so you know where you can work on the supporting brackets. Align the rail by using clamps, then align the fence next.
Check the alignment of the blade before you finish the fence up. Use an adjustable bolt for ease and convenience!
Step 8: Drill Some Holes
The last step involves drilling. Drill hanger holes into house trays by using the hole saw. You want to make sure you can put away everything you use on a wall. Finally, round the edges with a router. It makes your table look more polished! You can also avoid splintering and sharp edges. You want your workstation to be a safe place for your projects.
Now, let’s finish up. Sand the plywood to smooth everything down. Catch flakes and chips. Vacuum the area, then coat everything with polyurethane. When the wood contracts or expands, polyurethane will help mitigate warping. It makes your workstation visually striking, too!
Step 9: Finish Up, Call It A Day, and Enjoy Your Workstation
You can take a rest here or choose to install the saw into the workstation right away.
Congratulations! You’ve made yourself a table saw workstation. It’s less expensive, tailor-fit to your needs, and you have quality assurance. Try it out for yourself. If ever you see any flaws, you know which process made the results, and you can check over it quickly.
With a few tools, enough time, and hard work, you can have a convenient workstation for your table saw. Who says you have to pay shops and people hundreds of dollars to get things done? You can DIY it!
Before we wrap things up with this workstation guide, we have a few more tips. First, maintenance is a must. Aside from keeping your workstation clean, you can wipe it down every now and then. Apply sealers or varnish once a year, too. While we understand that maintenance can be hard to track, you need to do it! You want your workstation to last you years, not just a few months. Trust us; you’ll feel more motivated to maintain your workstation when it was built from your own hands.
However, don’t think that we’re discouraging you from buying a specialized workstation. Sometimes, we’re too busy – caught up in school, work, or family matters. It’s understandable.
Other times, the workstation that we need isn’t necessarily something that we can do. If your table saw workstation would benefit from a professional design and eye, then go for it! It’s best to let an expert take over for specialized table saw workstations. We just want you to save money if it’s a minimal workstation you can pull off.
We hope this article helped you out! Have you tried doing workstations in the past? What projects are you going to complete once your own workstation is done? Let us know about your woodworking experiences, comments, and inquiries. We’ll see you around!
Jason is a 40-year-old woodworker, carpenter and author who have been involved in the woodworking and woodcraft industry with 17 years of experience. He is expertise in technical aspects, woodcraft and furniture building projects.