Bosch Table Saw Custom Mobile Base

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Project by OakHill posted 02-28-2016 10:11 AM 2168 views 1 time favorited 2 comments Add to Favorites Watch

Purchased the WoodRiver Retracting Casters for the Bosch GTS 1031Table Saw mounted on top of the Bosch GTA 500 Stand.

As a retired Manufacturing Engineer, I knew when I purchased these casters that it would involve some major design issues. At first I thought it might be possible to build a frame around each of the legs of the stand that I could attach to the caster assembly. However, with the 1” square tubular legs and the compound angle of the legs I decided to design a new base for the table saw.

I started out by placing the stand on top of plain heavy duty packaging paper and found that legs of the stand are not square to each other. Each corner profile of the base shape had to be laid out separately. A 1 5/8 Diameter counter bore was placed below each leg to contain the stand on the base. A hole was added for a large diameter (1 ½”) adjustable rubber leg. Once the layout was complete I placed it on the floor, put the stand on top of it and added the table saw. This was done just to check if the weight of the saw would spread the legs and change the location of the counter bored holes. It did not change. I then transferred the layout to 3/4” plywood using carbon paper.

Next came the caster support block. These were made from 2×4 stock, planed to a clean surface and glued together. They were then trimmed and planed to a square block. The part of the caster assembly that holds the ball caster has to be parallel to the floor when locked in the down (movable) position in order for the casters to rotate freely. This resulted in an angle of 13 degrees which was needed on the bottom of the support bracket. To see what happens if you do not mount it at the proper angle, try moving the caster assembly around on the top of your workbench and watch what happens to the rotation when you tilt the assembly at different angles. The wheel jams and does not rotate freely.

Next I tested this idea on a makeshift setup (see picture) clamped to the workbench. It was determined that the bottom bolt hole had to be cut off and a new mounting hole drilled. Also by marking the top of the bracket in the open position with the caster resting on the “Floor” and then marking it again in the locked down position it showed that there was a total of .600” of stroke. I also determined (by trial and error) that a shim of ¼” thickness placed below the caster wheel in the unlocked position on the “Floor” would work for locating the mounting holes on the block.

Next was the positioning of the support block on the base, making sure there was sufficient clearance on the base for the swiveling of the caster in both the locked and unlocked position. I also relieved the base to position the caster as much as possible within the confines of the base rather than protrude out (about 6”) and take up shop floor space.

The base and casters worked out perfectly. Between the adjustable rubber leg and the counter bore in the base, the saw was raised only 1 1/16” overall. The added height did, in fact, seem to be a little more comfortable to work on.

The casters swivel smoothly and I never had a problem with them getting stuck or not rotating as some reviewers had experienced. The mechanism works great and is easily operated. The foot action for raising and lowering the casters works exceptionally well. A very well designed product from WoodRiver.

I used to manually lift the table saw with stand and carry it away from the wall. Now with a simple tap to the lever and a few seconds the saw is repositioned and ready to go to work.

These WoodRiver Retracting Casters get my five star rating.

Click below for review of WoodRiver Casters:

-- John, Illinois,

2 comments so far

View Jim Jakosh's profile

Jim Jakosh

22520 posts in 3466 days

#1 posted 03-23-2016 04:26 AM

Nice project!!!!!!!!


-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View RibsBrisket4me's profile


1554 posts in 2866 days

#2 posted 03-23-2016 10:59 PM

Yes, very , very nice!!

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