Workshop 2019 #8: Miter Saw & Compressor Cart: Part 2

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Blog entry by KettleWorkshop posted 06-20-2019 04:44 AM 239 reads 0 times favorited 0 comments Add to Favorites Watch
« Part 7: Miter Saw & Compressor Cart: Part 1 Part 8 of Workshop 2019 series no next part

So the cart is..mostly done. Or it was..

There is a crucial point when a plan/design meets reality.
At this critical point one of two things happen;
1)Everything goes great.
2)You notice problems you had not foreseen.

For my prior two projects (The Assembly Tables are technically done, just awaiting legs until the project is posted), everything went rather well. Didn’t run into any serious issues or need to step back and re-evaluate the project.

This one though…not the case.

With that, here is a list of the issues so far.
  • The height is a problem. While, as designed, it is at a comfortable height without having to bend over too much, it actually throws sawdust into my face.
  • The way the wings attach works really well and provides a strong support but there is inherently too much play in it. This makes keeping the fence aligned with that of the miter saw exceptionally difficult.
  • The wing attachment makes mounting the miter saw very difficult and only allows for the back holes to be secured. Clearly this is not ideal.
And here is all that went right.
  • The overall design of the side panels is fantastic and very strong.
  • The wing support arms work great and the use of an inverted leveling foot in a T-Nut works great for minor adjustments.

So what to do? How to solve? Well here is what I have come up with.

1) The sides and back have exactly 1’ of space below where the wing support arms attach. So I am going to disassemble it and cut those down, carefully, to bring the height down 1’

2) I am going to redesign the wings and how they attach and instead use some piano/continous hinges. I am going to make the fence much smaller so that they dont protrude as much from the sides when folded flat.

3) I am going to modify the top, where the miter saw sits, to make it recessed. This will allow the miter saw to sit down from the top of the sides, where the wings will be leveled to. And thus have the miter surface level with the wings without them needing to be built up in height to accomodate.

In the end, the surface of the miter saw should be roughly 1’ 3 1/2” lower than it currently is. Not uncomfortable but also less prone to spitting sawdust into my face. And the wings will be much less substantial but still strong.

So in memory of lessons learned, here is a picture of her as she currently exists.

The way I figure it, learning from these mistakes is part of the game. So it just means more work getting it right.

-- If you don't throw out the original design at least 2 times, you aren't finding all the imperfections.

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