Porter Sander 121 OSS - table saw right extension home #1: insert plate cut out and bolted to PC 121

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Blog entry by Holbs posted 04-03-2017 03:34 AM 1693 reads 0 times favorited 3 comments Add to Favorites Watch
no previous part Part 1 of Porter Sander 121 OSS - table saw right extension home series Part 2: Making "Y" shaped under table air flow cabinet and adding levelers »

Installing my Porter Cable 121 OSS into my Unisaw right side extension table. This will be my OSS sanding station / down draft table.
I needed a home for this PC121. I considered on the wall via french cleats, dedicated table, or a pull out drawer under my Grizzly combo sander station. To save space, I went with installing it in the extension table just as folks install their router station there. I was unsure of the spindle centering point so went with dead center middle between rails which suits my arm length fine for work. The spindle centering point is more to the right due to the underneath Unisaw right tilt motor cover opening. This should give me around 36”wide x 26”deep for down draft table purposes.
I ordered a “Phenolic Sheet, Opaque Off-White, 0.625” Thickness, 6” Width, 12 Length which is G10 class grade. I do not think this phenolic piece will EVER bend or sag. I had to cut out a 2.5” hole for the 2” sander sleeve and this piece took out my Milwaukee hole saw!

Ended up drilling 1/4” holes around and smoothing out with a metal wire wheel. Drill 6 more holes for the screws and counter sunk them with a forstner bit. Lots of smoke from all of this. Had to stop often and water chill my bits after every hole. I have 2 circular insets from my now-gone delta drill press drum sander kit. I may try to route out a circle to seat them, or maybe not. To level this insert plate, I ordered Kreg PRS3040 Precision Router Table Insert Plate Levelers since they were only $7 (I am hoping for all 4 instead of 1 piece!). Will give them a try out.

Later, will start to figure out how to make this a down draft table as well. How many holes using 3/8” bit (I think 400-500+ with my 6” duct on my 3HP DC), being cautious of the Unisaw motor opening and depthness of the PC121. Also, gotta make another insert out of hardwood or something so that when the PC121 is removed, I have something covering up the hole during palm sander work or when using PM66 (this area is the outfeed table for my PM66 and future miter slots).

-- The Carpenter Bee is derived from the Ancient Greek word wood-cutter "xylokopos/ξυλοκὀπος"

3 comments so far

View JayCee123's profile


200 posts in 1574 days

#1 posted 04-03-2017 09:55 PM

Multi-use tabletop is a good idea. It looks like your really coming along. Thanks for posting.

View jonlruss's profile


125 posts in 1922 days

#2 posted 04-05-2017 05:23 PM

Very cool! When I was planning my workstation I had the thought to get one of those and mount it on one of the extension ends but jeepers people want a lot of money for them. Nice to see one actually put to use that way.

View Holbs's profile


2363 posts in 2838 days

#3 posted 04-07-2017 12:36 AM

Jon..I snagged this PC121 new in box for $100 at a local auction. 2 years ago. Just now getting around to finding a true home for it :)

-- The Carpenter Bee is derived from the Ancient Greek word wood-cutter "xylokopos/ξυλοκὀπος"

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