My Garage/Work Shop Makeover #7: New Miter Saw Station

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Blog entry by MT_Stringer posted 06-29-2013 04:36 AM 10237 reads 6 times favorited 4 comments Add to Favorites Watch
« Part 6: Touch up painting and pegboard Part 7 of My Garage/Work Shop Makeover series Part 8: New Miter Saw Station - Construction Details »

My next part of the garage makeover is to build a miter saw station. I bought the plans from Ron Paulk and studied them over and over and watched his videos on building his work bench. So, I finally used Mikey’s Sketch pad to design my version of the miter saw station.

Here is my plan.

Sorry there is not a lot of detail in my plan but here is the jist of it.

  • Build two cabinets that will be used for storing power tools and larger jigs and leave room for short cut offs 24 inches or less. Use 3” locking casters on the front.
  • Add drawers or trays as necessary to make it easier to get to the tools such as the air compressor.
  • Position Shop Vac in the area under the miter saw.
  • Build the Ron Paulk version of The ultimate Miter Saw Station…with a few exceptions such as the width will be 24 inches instead of 18.
  • Attach the miter saw station to the cabinets with 3/8” bolts.
  • Build an extension table for the left side of the miter saw. Support it with Ron’s saw horse as shown in his plans.

All of this planning sounds good except, I have made slight changes as I went along. Hopefully for the good. I am mainly using Ron’s plans as a guide and to see his ideas of designing his bench and stand.

I have searched You Tube over and over watching videos until it all became a blur. However, I do like the ideas Jordan incorporated into his miter saw stand. I should also have room to set up my belt sander and maybe the oscillating sander. The more, the merrier.

Other inspiration came from the miter saw station built by Steve at downtoearthwoodworks.

Dust collection for this saw is #1 priority on my list. I already have the Shop Vac hooked up to it with the dust routed through the Oneida cyclone which works just great. I checked the vac and there is nothing but an empty bag in it. If I do set up a sander or two, I will most likely build some sort of short manifold so I can connect the tools to the Shop Vac also. That shouldn’t be to hard.

But the main thing I want to do is build some sort of hood to catch the airborne dust and draw it downward into a port that will be routed to my Harbor Freight Dust collector. That is a work in progress. I think it is doable because there will be about 6 1/2 inches behind the miter saw station that I can use for plumbing. :-)

Cabinet Construction
I have completed the carcases for the two cabinets. I used Birch plywood purchased from a lumber yard for $39.95 sheet. That is not too bad price wise.

Each cabinet has two sides and a center divider, along with a solid bottom. I connected these pieces with 4 inch stretchers also cut from the plywood and everything was joined together using pocket hole construction. Since I want these cabinets to be strong, I used some 1/2 inch plywood left over from another project to fill in the back of each cabinet. I used the Kreg micro pocket hole jig to drill the 1/2 inch pockets and one inch screws. That made the cabinet very strong.

I mounted some plywood pads under each corner of the cabinet to give the casters some extra meat so the lag screws will get a good grip.

And here we are, up to date. Both carcases are ready for drawers and face frames. I have them set in place and mocked up the saw, air compressor and the shop vac.

After the initial dry fit, I realized that I probably should shorten the overall length a few inches and leave room for the dust deputy to sit at the end which will make it really easy to empty. So I think I will shorten the miter saw Station overall length to 80 inches instead of the original 90. After doing some preliminary measuring, I will be able to have about 8 1/2 inches of full support for whatever I will be cutting with about 37 inches to the right of the blade and about the same to the left. With a short extension, I will be able to support a full 8 feet to the left of the blade and still have the garage door down. To the right, I can go out over 12 feet with no problem.

That brings the project up to date. I think I will ponder the situation and maybe go to the store and check out the HVAC metal stuff. Hopefully, I will be able to fit in the duct work so I can rout it to the dust collector.

I forgot to mention that the miter saw is brand new. I sold my original Harbor Freight model and bought the Hitachi 12 slider from the Big Box Store. So far, I really like it. Smooth, not too loud and the factory blade works surprisingly well. The main reason for purchasing the saw new was to gain about three inches of wall clearance with the two position slider. Maybe I can do a review after I have had it for awhile and get used to it.

-- Handcrafted by Mike Henderson - Channelview, Texas

4 comments so far

View steliart's profile


2895 posts in 4178 days

#1 posted 06-29-2013 01:02 PM

Excelent liter saw you have their and the projects looks great

-- Stelios L.A. Stavrinides: - I am not so rich to buy cheap tools, but... necessity is the mother of inventions !!!

View helluvawreck's profile


32122 posts in 4357 days

#2 posted 06-29-2013 01:07 PM

It’s really nice and will give your shop a lot of organization.

helluvawreck aka Charles

-- helluvawreck aka Charles,

View NormG's profile


6576 posts in 4494 days

#3 posted 06-29-2013 04:48 PM

I started this reply yesterday, had to watch Steve’s video, you did a wonderful work station, thank you for sharing

-- Norman - I never never make a mistake, I just change the design.

View Roger's profile


21055 posts in 4294 days

#4 posted 06-30-2013 01:08 PM

Coming along nicely

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed. [email protected]

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