Drop Down Panel Cutting Station

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Project by uMinded posted 07-06-2015 12:18 PM 2808 views 21 times favorited 5 comments Add to Favorites Watch

I was trying to rip a 4’ x 8’ sheet of 1/8 hardboard lengthwise on my tablesaw and it was a disaster. I got to thinking that I needed a better way of parceling sheet goods to rough size before heading to the table saw. I also know that my floor space is disappearing quickly (Thats a telescope on that hand cart, lol)

This was all made with things I had on hand. Total cost of $0, my favorite!

2×4x10’ cut a 15deg angle on the bottom and cut to 100” give a perfect fit to my 8’ ceiling. I then cut two scrap 2×4’s to their max length (the inside ones) and used a forstner bit to plow a 7/8” hole through them in two locations. I slid everything onto two 5’ pieces of 3/4” electrical EMT and screwed a deck screw into the wood/pipe to secure everything. The bottom support is a scrap french cleat from MDF. Hinges are just some from a door I found in the alley, drilled out so there are 3 screws into the 2×4.

When cutting lengthwise I clamp the top of the sheet to the four 2×4 supports and manually cut the panel with my circular saw. (not the most accurate but 1/4” waste is doable) When the panel is cut the top section stays floating so there is no binding on the blade.

Cutting crosswise is much easier. I simply use my circular saw jig and put it on the line, clamp wherever is convenient and rip away.

To put it away I mangled some 4” rubberized lag hooks into “L” shapes. I simply hold the unit up and twist the L to support the 2×4.

5 comments so far

View Desert_Woodworker's profile


1953 posts in 1775 days

#1 posted 07-06-2015 02:51 PM

I love “panel” saws- I enjoyed your creation.

-- Desert_Woodworker

View scott0317's profile


58 posts in 2016 days

#2 posted 07-06-2015 03:20 PM

Thats a pretty slick solution to a common problem. I was dealing with the same thing this weekend and thought also, there has to be a better way without giving up the space for a panel saw station. I too am fine with just getting the 4×8 to a manageable size to then finish cut on the table saw.

Thanks for sharing this idea. Let us know if you end up adding to it to make it better, if you don’t mind.

-- I've almost got all the tools I need, almost.

View stefang's profile


16862 posts in 3895 days

#3 posted 07-06-2015 04:19 PM

Very cool solution.

-- Mike, an American living in Norway.

View eTodd's profile


7 posts in 1618 days

#4 posted 07-06-2015 11:43 PM

Clever solution to hang from the ceiling, well planned and executed to miss the ceiling light. Appreciate you sharing your solution.

-- eTodd

View JRAP's profile


103 posts in 2510 days

#5 posted 07-07-2015 11:57 PM

Great job. I love simple, yet clever ideas like yours.

I had the same issue with needing a more manageable way to cut larger sheets down to size, and I went this route

Guess it’s true… there’s always more than one way to skin a cat.

-- -- Jim, Cumberland,RI -- Life is all the other stuff you do when you're not in the shop. -

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