A new look for an old workhorse.........!!

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Blog entry by Rick Dennington posted 05-05-2010 07:14 PM 28090 reads 27 times favorited 28 comments Add to Favorites Watch

Greetings all: I’ve had this old Sears contractor saw for 26 years, and it served me well, and still serving me well. After about a week of having it, I knew it was time for a new make-over then. So I took off the old “diamond” wings, (I hated them things..pinched my fingers everytime I used the saw), removed the crappy fence, and went on a “search and destroy” mission. After checking around for the best fence that would fit the saw, I settled on a Delta Precision SawGuide w/ 30” rip capacity. After getting the new fence, it was time to build left and right outfeed tables. The left table was standard… 12” x 27 ”.... The right was 25 1/2” x27”. Both were MDF and laminated. These old saws didn’t have any left of the sawblade cutting back then, so this was perfect. The onlt thing I didn’t change was the old crappy metal legs that came with it (I wish I had of then).
This sucker was dead-on accurate for all that time, and still is today…... But, after 26 years it was time to update. So last July I bought a new ‘09 5 h.p. Delta Unisaw w/ 52” r.c…. this sucker’s a beast. All the while I was still using my old Sears for dados and rabbits. Works great… When I finally got caught up this winter on some customer projects, I looked at the saw and said” it’s time for a make-over. So I took everything off, stripped it down to nothing but the saw body, and started…. First thing I did was design a set of cabinets, and how they would fit. One thing I had to keep in mind was that the saw couldn’t be any higher than the outfeed table for my new saw, since it’s backed up to it to use that table. After much calculations and head-scratching, and knowing it had to be at least 1/4—- 1/2” LOWER than the o.f. table, I went to work.
I built 3 seperate cabinets, all out of 3/4” B.B ply. They had to be the same height and depth as the saw body.
Two of the cabinets are the same.. the left and middle, but the right one was bigger to handle the o.f. table.
Ovewr-all dimensions are 20” deep, and 60” long. The first thing I built was a roll-around support platform w/ 3”
locking casters, w/ a support grid underneath to support the weight of the saw, only…. Cabinets are 19 1/2” high x 20” deep. The middle cabinet is for dust collection. I cut a hole the same size as the opening in the sawbody to let the sawdust fall into a pull-out drawer, and left a wide lip to mount the sawbody onto. No dust collection hook-up for this one….. All drawers have full extention slides, except the sawdust collection drawer
(it has a false front on top), and I just pull the drawer out, empty it, and slide it back in….. works good.
The back is completely enclosed to contain sawdust since I don’t tilt it for anything. All the wood trim is maple, and has 3 coats of Tung oil finish….. I had needing to do this for a long time, and finally got around to it during the winter. Didn’t mean to drag this out so long, but wanted to give a good explanation of how it’s built…..
Thanks for looking, and if you feel the need to build one of these, go for it…....... If you have any questions, just PM me, and I’ll try to answer them…...

-- " There's a better way.....find it"...... Thomas Edison.

28 comments so far

View Abbott's profile


2570 posts in 4796 days

#1 posted 05-05-2010 07:16 PM

Very slick!

-- Ohh mann...pancakes and boobies...I'll bet that's what Heaven is like! ♣ ♣ ♣ ♣

View ajosephg's profile


1909 posts in 5053 days

#2 posted 05-05-2010 07:30 PM

I like that

-- Joe

View Kent Shepherd's profile

Kent Shepherd

2718 posts in 4779 days

#3 posted 05-05-2010 07:32 PM

Great looking cabinet Rick



View Cory's profile


760 posts in 4912 days

#4 posted 05-05-2010 08:10 PM

Excellent work as always, Rick. I wish I had the luxury of two saws!!!

-- The secret to getting ahead is getting started.

View Cozmo35's profile


2200 posts in 4528 days

#5 posted 05-05-2010 10:47 PM

SWEET! Nicely done! I want one!!

-- If you don't work, you don't eat!.....Garland, TX

View Marc5's profile


304 posts in 4834 days

#6 posted 05-06-2010 02:37 AM

I hope you don’t mind but i may use some of your design for my saw cabinet. I like it.

-- Marc

View Rick  Dennington's profile

Rick Dennington

7232 posts in 4687 days

#7 posted 05-06-2010 04:36 AM

Greetings Marc5:....... Thanks, Marc for the comment….. I kinda like it too…... I certainly don’t mind at all. Use some or all of it if you like. I got the idea from a couple of different sources myself, so it’s not original. One pixs I didn’t post was of the support base…I forgot to show it. It has a torsion box construction which gives it good support of the sawbody. That’s really the only real weight on the base….... therefore no sag or give…. If you build one, I think you’ll be real happy with it… I know I am…......

-- " There's a better way.....find it"...... Thomas Edison.

View redryder's profile


2393 posts in 4594 days

#8 posted 05-06-2010 07:50 AM

One thing I like is lots of photos from all angles and you delivered my friend. I like the toe kick being under the saw so you can get close when you want. I usually dance around the after market rollers and rails I put on mine. That’s a great do it yourself project…..

-- mike...............

View BritBoxmaker's profile


4611 posts in 4529 days

#9 posted 05-06-2010 08:31 PM

Brilliant blog. I’m a firm believer that old faithfulls should be reworked in this fashion. Its served you well now you’ve done the same for the saw. Well done on the project.


-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging.

View Rick  Dennington's profile

Rick Dennington

7232 posts in 4687 days

#10 posted 05-06-2010 08:56 PM

Greetings Martyn:.... Thanks….. I guess I just like to talk too much, but I also think that blogs and projects need some good description, along with pixs, and a good explanation of how the work was done… that leaves nothing to be desired from the reader…... I say give them the works…. lol.. I want to see it all when I read about something I like… These one-liners don’t cut it for me: ” Ok, here’s my project” just ain’t gonna get it…..

-- " There's a better way.....find it"...... Thomas Edison.

View Dennisgrosen's profile


10880 posts in 4608 days

#11 posted 05-06-2010 10:23 PM

that is a heavy upgrade to that saw
well done both with the build and the blog


View Rick  Dennington's profile

Rick Dennington

7232 posts in 4687 days

#12 posted 05-27-2010 05:24 PM

Greetings all, A little update on something that happened last night….. I was watching the Cardinals play the Padres last night, the phone rang, but I didn’t answer it, cause I let the answering machine kick in. The message said” I would like to buy your tablesaw station if you would be interested in selling it. I saw it on Lumberjocks, and since you have two, thought maybe you’d sell that one”. When I looked at the number, there was none….
It said “not provided”, and all zeros for the number….. very strange, indeed. I figured they had to be a LJ, but the call puzzled me. So…. I am wondering if any of you guys (or gals) called, and if so why didn’t you give a name and number so I could call you back? I’ve never had a call like that before…. very very strange, indeed.

-- " There's a better way.....find it"...... Thomas Edison.

View a1Jim's profile


118333 posts in 5070 days

#13 posted 05-27-2010 05:29 PM

Good work Rick a very slick set up . a great job.


View Delta356's profile


463 posts in 4346 days

#14 posted 10-20-2010 04:34 AM

Very nice, and great looking cabinet.

Thanks,Michael Frey
Portland OR


View Schwieb's profile


1925 posts in 4954 days

#15 posted 01-22-2011 09:37 PM

I am curious about the fixtures on the base to secure it to the floor while using the saw. I couldn’t make it out too well in the photos as to how they work. Can you direct me to a catalog source? I’m designing a similar kind of rolling cabinet and wanted to be able to secure it to the floor during use.

Very nice shop cabinet. I love it when someone builds nice shop fixtures.

-- Dr. Ken, Florida - Durch harte arbeit werden Träume wahr.

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