WIP - Mitre saw workstation - Completed

[Lee J]

Way back in June this year I was pondering on building a workstation for my mitre saw. Now my mitre saw is only a cheap one, it doesn't even have a sliding function (tut tut), however I will be replacing it very soon with a sliding mitre saw. I dreamed of a workstation with some storage, support for longer timber and on wheels so I could scoot it around the workshop. Then as if by magic the postman launched my July issue of Woodworker magazine through my letterbox. I flicked through it whilst having a potta tea. Well, go to the foot of our stairs! In there was Keith Smith building a Mitre saw workstation!!

So I am going to follow Keiths build notes as close as I can. However I may alter somethings slightly along the way, to suit my needs more.

I thought it was only right I did a WIP for you all to follow, now the nights are drawing in and your all that bored. lol

This will be completed as quick as I can as I have a few jobs that need to be complete for Christmas this year.

Let battle commence...


I set about sourcing some sheets of 12mm MDF. B&Q came up trumps. I got the biggest sheet I could and made use of the 'first 4 cuts are free' option. I'd already mapped out the cuts to be made and they made them and reduced the huge board down to managable sizes.

I got it home, laid the first piece onto the bench (remember the bench? I did a WIP on that too) and started marking out the pieces. Then I remembered I had forgot the most important part of preparing ANY job...

ahhhhhhhh! now I can start! Where was I? oh yes, marking out...

I then set about cutting the pieces. To cut them I used one of these guide clamp objects...

...and my trusty B/Decker XT1600...

I started to assemble the pieces. Now Keith uses 18mm MDF but I am only using 12mm MDF so all the measurments of pieces had to be recalculated. However, I seem to have got them right cos they all fit.

I attached the back to the base, then the 2 sides...

Then the top bit...

For ease of assembly I'm using Titebond and my nail gun to quickly assemble the carcass. Once it's together I went around and drilled/screwed the panels securely.

Thats it for now, more to follow.

 

[OPJ]

Ah, yes, I also recall seeing that article. This will be a very interesting thread to follow. :wink: The only thing I didn't like about Keith's design was that in using drawer slides/runners (which, alone, is a great idea) you are limited to approximately only 600mm extra support either side of the saw... I look forward to seeing what changes you make though.

Last year, I made my own based on some American plans (FWW or PWW - I forget which! :roll. Hinging the tables saves space but, if I was to do it again, I'd try and source some thicker piano hinges. Or, replace the cheap, flimsy steel things with a series of butt hinges. Also, you need clearance either side of the saw in order to swing them up. Yes, I may be stating the obvious but, it becomes a right PITA when your workshop's full! :x

By the way, it's good to see that you're sorting out your workshop (first you 'bench and now this) before you get carried away trying to build things and store timber!

 

[big soft moose]

By the way, it's good to see that you're sorting out your workshop (first you 'bench and now this) before you get carried away trying to build things and store timber!

thats one philosphy - but some of us prefer to imediately fill the shop so full of free timber that we can hardly move , then wind up building bookcases in the living room

 

[wizer]

I'd love to have a dedicated mitre saw station. But I dont have the room in my workshop. Too much other stuff shoe horned in

 

[Tony Spear]

then wind up building bookcases in the living room

Bookcases? :lol:

Pah! The latest thing to get built in my living room was an effin' gert porch canopy! :shock:

 

[OPJ]

then wind up building bookcases in the living room

Bookcases? :lol:

Pah! The latest thing to get built in my living room was an effin' gert porch canopy! :shock:

LOL - that reminds me of an old episode of The Simpsons, where Homer's planing shavings from his 'Wonder Bat' - "Homer, come to bed..." "Go back to the garage, Homer!"

 

[Lee J]

Tonights installment went slowly. I seemed to get distracted by other smaller jobs as I was going along. I'd do 5 mins on this then I'd notice another job that needed doing or summat, but I managed to get some work done.

First job was to screw this carcass together. Remember it's only been held with Titbond and small nail/tack things at the moment. I picked up a box of MDF-tite screws from Screwfix and set about screwing it together. I wasn't looking forward to the prospect of drilling a pilot hole then swapping the drill bit for a countersink bit so on and so on. Then I remembered I have one of these...

Sorted! I can drill hole and sink at the same time - result!

I ran 3 screws across the top, 3 across the bottom, a couple up the back edge and 4 along the back.

Next up, I needed to cut out a notch for the front panel to sit in. I marked it out with my square...

...then cut the notchs with a small saw...

Now the front panel fits in, I ran a piece from front to back, glued and screw the both together...

next job will be trim the edges flush on the front upright panel.

Thats all I got done tonight. I got distracted cleaning the rubber castors up that will eventually go on the bottom of this. I've reclaimed them from a unit I found in a skip. lol

 

[Lee J]

Hope you all had a nice weekend!

I made some progress on Saturday. Started with a brew :wink: and a bacon buttie...

then it was into the workshop (garage) and first thing to do was put the top on. I call this the top but in actual fact it's the base where the saw will sit. Things must be going to plan as I actually cut this peice before I started the assembly and it fit really snug.

I have fixed the top/base with screws. This is because I will have to remove it to fit some drawer runners as soon as I get some. Struggling to find some 300mm drawer runners/slides.

Next I fit the 2 upstands...

...and the sides and tops to complete the upstands...

Once again, this is all just held together with panel pins due to the fact I will need to dismantle it later.

I will be on with cutting the drawers tmrw night (tuesday).

Coming together nicely.

 

[OPJ]

Struggling to find some 300mm drawer runners/slides.

Have you tried Toolstation or Screwfix?

If you can get longer slides then, I'd recommend it, if only for the extra capacity and work piece support.

 

[Lee J]

I did try Screwfix Olly but they didn't have the type that come apart so I can fix part of the rail to the carcase then part of it to the drawer seperatley.

I've ordered some from flea-bay now though, £4.99 for a pair.

The depth of the drawer hole I have is 400mm, so I figured 300mm was safe enough.

 

[Lee J]

Been a week or so since I did anything on this project so I got an hour in last night. I had received my drawers runners and these turned out to be a bargain. I bought them off eBay from bullard_ltd, £4.99 a pair.

Anyway, after a lot of careful measuring I set about cutting the peices for the drawer sides/back/front. these will be biscuit jointed. The feature I'm following in the magazine used Pocket Holer for this job but since I don't have one I reckoned small biscuits would be good enough. I cut the pieces for both drawers . The bottom of the drawers will be made from 12mm MDF too. These will be screwed in place through the sides/back/front. I didn't get to cut the bottoms as I need some more MDF. That'll be tonights job.

So I moved onto the runners. Because I'd dry assembled the top parts of the cabinet I needed to dismantle some of it to get into the drawer spaces to fit runners. Once I'd done this I placed a piece of 12mm MDF as a spacer between the bottom of the runner and the cabinet. I set the runner 10mm back from the cabinet front and screwed the runner in place. I stood the side piece on a 5mm spacer to lift the drawer bottom off the cabinet, marked the runner on the drawer side then screwed the runner to this.

Here are the 2 side pieces slotted into the runners...

At this point I put the back and front on too, not permenent, just so I could see it as a drawer...

and that was it. More to follow tmrw as I've got a few hours in the workshop tonight trying to get these drawers done.

supper time..

 

[Lee J]

Another installment last night. Took 2 hours out in an attempt to get these drawers near sorted.

First job...

SLUUUURPPPP... Righto, I cut out the side drawer bases from 12mm MDF. I was gonna rout a channel around the inside of the drawer sides and slot in some thinner ply but I reckoned for what this project is a board of 12mm MDF, screwed and glued, should be sufficient.

I laid the sides on the MDF and drew around the inside, then cut it out with my B&D jigsaw, and finally I ran a hand plane across the cut edge to remove any wobbles.

I glued up the edge the tacked each edge into place. then when I was happy with the squareness I run a screw through to secure the drawer...

I did the same for the other side and fit the drawer runners. Now came the fun bit, hoping that I'd measured everything right...

...I slotted the drawers in place...

BINGO!

These side drawers serve 2 purposes. I will use them to store spare blades and other bits and bobs but they will have uprights on them so that when fully extended they act as support for long pieces of timber.

I assembled the rest of the cabinet and properly fix it all in place using screws and glue...

Drawer shut...

Drawer extended...

I now decided I would make a drawer to go in the front. This drawer would be full width and depth of the cabinet but about 100mm high. I used the same method as the side drawers earlier except I drilled 2 finger holes in the front to allow me to open it. Here is the finished drawer ready to be mounted...

I am going to use wooden rails for the drawer to sit on as I made a boo boo and forgot to account for the drawer runners. I made the drawer about 4 mm smaller than the hole - dohh. But this doesn't really matter.

Hopefully Sunday I'll get a few hours to make the upstands for the side drawers, fit the front drawer, fit the wheels and think about finishing it off.

any ideas for a finish?

 

[OPJ]

You can never have too many drawers, Lee!!

As for a finish... Normally, I'd recommend first applying a coat of Rustins' water-based MDF sealer. But, if this is MR MDF then, it may not be necessary as it doesn't seem to soak up liquids nearly as much as the regular grade.

You could prime and paint it white, which brighten the place up a bit...? :wink: Otherwise, I guess you'd be looking at some kind of varnish or lacquer for further protection.

 

[Lee J]

What type of varnish would you recomend Olly? I've seen vernished MDF and I quite like the look, I also have my MDF bench top I need to varnish too. This is normal grade MDF - nothing fancy

 

[wizer]

Paint it white Lee

 

[Lee J]

OK boss! lol.

So MDF primer + an eggshell Paint?

 

[wizer]

no just undercoat and eggshell, all my workshop units are treated this way. no need to prime

 

[Lee J]

interesting, just ya normal undercoat and eggshell - I'll bear that in mind for tuesday night when I paint it.

completed this now, WIP to the finish will be added later this morning

 

[Lee J]

Bit of a rainy day today so I took a couple of hours and put them to good use in the workshop. Liverpool vs Man.Utd just kicking off on Radio 5 Live, so as a Liverpool fan it couldn't be a better day to be in the workshop - radio on of course!

Gonna try to get this saw station completed today, need to move on to the next project ASAP, here's the job list for today :

1: Pot of tea
2: Fit the big drawer
3: Complete the upstands
4: Fit the wheels
5: sand the whole thing

Best crack on then...

1: Pot of tea

2: Fit the big drawer

I decided to just use MDF rails attached to the sides for runners instead of the proper metal drawer runners. I did intend to use the proper runners but I messed up when I made the drawer and didn't allow for the depth of the runners. dohh.
So I cut some runners and attached accordingly...

I run an old candle down the edges too, to lubricate. The drawer fitted well. A little too well to be honest, it's a bit tight but I'm hoping it'll wear in a bit.

3: Upstands

Cut a peice for the ends...

Then cut some for the sides...

Then I topped it off...

So, here is a few pictures now the carcass is complete...

4: Have wheels will travel!

Decided to fit the castors as close to the edges as possible for maximum stability. Now normally I would've used scres but I didn't have any short enough but fat enough to fit so I opted for bolts. This will mean I will have bolt heads inside the large open storage area below but I can't see it been a problem.

5: Sanding time

GET IN THERE!!! Liverpool 1 - Man.Utd 0

Righto, time to sand it. I decided to sand all the sharp edges off the carcass. I loaded up my power sander with 120 grit and set about it. Suprised how good this actually looks to be honest...

RESULT! Liverpool 2 - Man.Utd 0

So apart from some primer and a coat or 3 of eggshell white this is complete. Later I may make some more drawers for it to fit in the front. I need to fit my mitre saw but I'm debating whether or not to purchase a new one, hmmm.

Hope this proved interesting for some of ya, I got the inspiration and the design from the Woodworking mag.

Jobs-a-good 'un