R4511 table saw base...

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Project by KTMM (Krunkthemadman) posted 08-12-2010 07:55 PM 12360 views 31 times favorited 17 comments Add to Favorites Watch

This is my version of a table saw workstation which is set up for my specific needs….

Building this has been bittersweet to say the least.

To begin with, I took all the needed measurements of the saw and space needed to install the router table. I used sketchup to draw the entire thing up and plan out cutlists and such. This was fun, being the first time I’ve really made anything in sketchup. The base was made to fix two problems that I had, 1) I wanted a router table that could put the Incra to use, and 2) I was hoping to add stability to the table saw and provide a place to store all the table saw accessories.

Let me start by saying that I didn’t cut anything too short in the building of this project, which is a first for me. But, that is only good to a certain point. I originally built the base using two 2’x6’ sheets of plywood, screwed to a 2×4 frame with casters at either end. This lasted until I “demonstrated” it’s sturdiness to a friend by jumping on it, (at the time all 210 lbs of me) which managed to splinter the frame at both ends. I think my ego was hurt more than anything at this point, and back to the drawing board I went. I contrived using more screws, a jug of Titebond, and even a healthy dose of duct tape. In the end I just decided that four 6’ lengths of 1-1/4 angle iron strapped to the base would be more than enough to keep the base from flexing. I attached these with a handful (think Grizzman handful) of lagbolts excessively torqued in good woodbutchering fashion. I invited my friend back over and we both proceeded to stomp the base to our hearts content, this time, it held.

The next step was the cabinetry, originally there were going to be two cabinets. The one you see on the end, and the one in the center. I built and installed the one on the center, it was made of MDF. This wound up making the base too heavy, and after sitting for a minute or two, it would “settle” into the wood floor of the shop. Long story short, I had to remove it to be able to move the saw and base.

The final problem came with the router table extension. I cut, glued, and laminated it. The thing is made of two 3/4 sheets of MDF glued together. IT IS HEAVY. It wasn’t until I had it installed that I realized I should check the deflection of the top. Luckily the router side is perfect up until just behind the mounting plate. The part of the extension where it mounts to the saw is deflected about 1/16th of an inch downward on either side. (At the front and back of the saw). I’ve learned to live with it.

Also, I had planned to put doors on the router table part, but I realized that in my small shop they wouldn’t open very well if I moved the saw towards the opposite wall. It was at this point I decided this was finished.

At this point I have plans for a new and improved version of this…....

OH YEAH, I forgot to mention, the router extension is not supported by the incra rails. I didn’t believe that the granite on the saw could support the weight by itself. So on the router table side, I put three 3/8 in threaded inserts in the top of the cabinet, and ran some bolts from the bottom up. Instant stability and micro-adjustability. The original center cabinet had 6 more adjusters in it. It made. leveling the extension up a breeze.

-- Practice does not make perfect. Only perfect practice makes perfect. Vince Lombardi

17 comments so far

View BillyJ's profile


622 posts in 3717 days

#1 posted 08-12-2010 08:08 PM

I think it is a great workstation. I like the many storage spaces – I know how handy all of them will be. Having the blades readily accessible is great – that’s something I need to do also. Great job.

The Incra system is awesome – isn’t it? I had one on my last TS, but it left when I sold the Jet and purchased a Delta. I miss it!

-- I've never seen a tree that I wouldn't like to repurpose into a project. I love the smell of wood in the morning - it smells like victory.

View Sailor's profile


543 posts in 3779 days

#2 posted 08-13-2010 01:29 AM

Thats definately cool, I would like to have one of these stations for my saw because…... well just because I guess, and it looks cool! Great job…

-- Dothan, Alabama Check out my woodworking blog! Also my Youtube Channel's Facebook page

View Chips's profile


199 posts in 4227 days

#3 posted 08-13-2010 01:41 AM

That’ a boss setup. Envy

-- Make every day the best day of your life. Chips, Mississippi

View shimster's profile


96 posts in 3521 days

#4 posted 08-13-2010 03:37 AM

Makes me realize how much money I’m going to need to drop into my R4511 to get it tricked out like this. First step: I guess I should unpack my R4511.

-- Less is More.....expensive

View nuzzo's profile


64 posts in 3631 days

#5 posted 08-13-2010 03:41 AM


View KTMM (Krunkthemadman)'s profile

KTMM (Krunkthemadman)

1058 posts in 3708 days

#6 posted 08-13-2010 04:23 AM

The sad thing is, up until yesterday, I was debating on selling or trading the saw….

That was, until I had to do a bunch of cuts last night. The table pictured behind my saw has been converted into an out-feed table / planer cart. At this point, I can roll the whole assembly against the wall when I need floor space.

-- Practice does not make perfect. Only perfect practice makes perfect. Vince Lombardi

View ChuckC's profile


843 posts in 3449 days

#7 posted 08-13-2010 05:16 AM

That’s great! How do you like the granite top on that saw?
I like the fence too but you need a lot of space to use it.

View Brandon's profile


4152 posts in 3466 days

#8 posted 08-13-2010 07:00 AM

Great work! I might try a smaller version of this, since I don’t have the space for all that rip capacity.

-- "hold fast to that which is good"

View webwood's profile


626 posts in 3764 days

#9 posted 08-13-2010 05:55 PM

sweet setup – love my incra routerfence

-- -erik & christy-

View Ken90712's profile


17750 posts in 3703 days

#10 posted 08-13-2010 06:12 PM

Great project like the way you did your blades! Going to have to use that thax for the great ideas!

-- Ken, "Everyday above ground is a good day!"

View KTMM (Krunkthemadman)'s profile

KTMM (Krunkthemadman)

1058 posts in 3708 days

#11 posted 08-13-2010 06:27 PM

Granite tops are great, the only drawback is that I have some chipout on the left miter slot mouth. I am eventually going to hit Ridgid up for a replacement top since it was like that when I got the saw.

One thing that I am going to do is replace the router table extension and make it so that I don’t have to flip the TS-LS around to use it.

The saw holder was originally wall hung, the angle was supposed to be 25 degrees, but I cut the slots at 45. Worked out in the long run as you can see.

-- Practice does not make perfect. Only perfect practice makes perfect. Vince Lombardi

View aurora's profile


234 posts in 3766 days

#12 posted 08-14-2010 03:03 PM

slick saw station. i like your ideas.

View ugoboy's profile


118 posts in 3548 days

#13 posted 08-17-2010 06:43 AM

nice job!

-- ~ Guy Woodward, Pflugerville Texas

View KTMM (Krunkthemadman)'s profile

KTMM (Krunkthemadman)

1058 posts in 3708 days

#14 posted 10-15-2010 06:14 AM

The bad news guys, I sold this saw about two weeks ago. The good news, I have room in my shop, and I’m restoring an old saw / making a new base.

-- Practice does not make perfect. Only perfect practice makes perfect. Vince Lombardi

View KTMM (Krunkthemadman)'s profile

KTMM (Krunkthemadman)

1058 posts in 3708 days

#15 posted 02-09-2012 05:08 AM

Wow, what a progression from that to what I have now…. I need to post the updated pics of my shop….

-- Practice does not make perfect. Only perfect practice makes perfect. Vince Lombardi

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