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Table Saw/Router Table Cart Modification

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Project by SplashMaster posted 04-10-2021 03:46 PM 696 views 1 time favorited 20 comments Add to Favorites Watch

Over the course of last year I have focused in on upgrading the table saw/router table cart. It all started whit the fence system. After shopping around an looking at the few options for fence upgrades I chose to go with the Vega U50 Table Saw Fence System, witch has a 50 inch rip capacity. This has made a big difference in ease of use and repeatability of this old Craftsman 113 saw. (Ironic that the fence cost 3 times as much as the saw lol) I would certainly recommend it to anyone looking a fence upgrade and the do make a 36” version if space is a concerned. Also one nice feature of the fence is the metal plates on it to attach the extension wing. That made the process straight forward and relatively simple, Just a top with some bracing for support.

With that completed I turned my attention to the router table wing. Since I had to remove the original I decided that this was as good a time as any to splurge on a router lift. While the router plate I was using worked it left a lot to be desired and was had quite a bit of vibration in it when using large diameter router bits. So, I chose the JessEm Rout-R-Lift II witch is the least expensive lift I could find and as far as I can tell the main difference between it and other models is the top is made from 3/8” hard board instead of aluminum. Since I have been using it for about a year now I have been very pleased with it and would certainly recommend it to anyone else who like me can’t justify paying for more expensive models. I then added the aluminum 3/4” miter bar channel witch has been a great modification for using jigs and such. I am still using the original fences I made for the router so I don’t have to worry about tying up the Vega fence every time, but the Vega fence dose reach the router and works great with it. To turn the router on and off I added a generic paddle switch and wired an old 15’ shop vac electrical cord to it, so it can be plugged in no matter where it is parked in the shop.

With everything back in working order I turned my attention to an outfeed support wing. The Vega fence made this rather easy as I could attach a 2” X 4” board to the under side of the square metal tube and then affix a framed plywood top to the 2” X 4” and add some plywood supports down to the cart base one either end. Then I routed the relief dados for the miter slots of the table saw.

The last four thigs I did were adding a pice of 3/4” PVC pipe to the left side to hold the miter gauge, added a shop vac hose fitting to the back of the saw cabinet fore easy hookup dust collection, closed off the back of the saw with 1/4” plywood and card board to help the dust fall to the vacuum hose (I got this idea form rockusaf here on LJ https://www.lumberjocks.com/projects/414473), and added some wooden holders for the router table tools and throat plates. I did add a magnet to hold the wrench in its slot and it works great.

As for the original base cabinet I am still very pleased with how I originally made it. The shelf over the drawers is a great place to store jigs and push stick’s. The cheap 5” amazon casters still make moving it easy and it locks in place very well. The dust bin door was worked out very good but some hinges would make its use more convent (maybe another future little upgrade).

While I would like to have a big cabinet table saw and dictated router table, this option (even with the expensive upgrades) is still a lot more affordable and work very well in my weekend work shop. Price break down Saw $100, Fence $350, Router Lift $162, Casters $26, Paddle Switch $10 and I think the router was on sale for $80 when I purchased it 4 years ago. Everything else was left over form other project (plywood, drawer hardware, ect.) And the good thing about doing thins this way is didn’t have to buy it all at one time, spacing it out over a few years.

Thanks for stopping by and let me know if you have any questions or upgrade suggestions you would recommend,
Matthew Stillwell





20 comments so far

View BurlyBob's profile

BurlyBob

8882 posts in 3352 days


#1 posted 04-10-2021 04:13 PM

That’s really impressive. Well done there.

View SplashMaster's profile

SplashMaster

309 posts in 3948 days


#2 posted 04-10-2021 04:44 PM

Thank you Bob!


That s really impressive. Well done there.

- BurlyBob


View mtnwild's profile

mtnwild

4056 posts in 4614 days


#3 posted 04-10-2021 05:29 PM

WOW, that’s some designing, and work into that…Worth it by the finished product…Well done…

-- mtnwild (Jack), It's not what you see, it's how you see it.

View Andybb's profile

Andybb

3279 posts in 1690 days


#4 posted 04-10-2021 05:34 PM

Very well designed, very compact and very mobile. The Trifecta!!! Perfect for a garage shop setup.

-- Andy - Seattle USA

View SplashMaster's profile

SplashMaster

309 posts in 3948 days


#5 posted 04-10-2021 05:37 PM

Thank you Jack, it certainly has evolved well over time.

WOW, that s some designing, and work into that…Worth it by the finished product…Well done…

- mtnwild


View SplashMaster's profile

SplashMaster

309 posts in 3948 days


#6 posted 04-10-2021 05:38 PM

Thank you Andy


Very well designed, very compact and very mobile. The Trifecta!!! Perfect for a garage shop setup.

- Andybb


View mafe's profile

mafe

13189 posts in 4176 days


#7 posted 04-10-2021 08:04 PM

Lovely setup, really looks like a heart of a shop.
Best thoughts,
Mads

-- MAD F, the fanatical rhykenologist and vintage architect.

View SplashMaster's profile

SplashMaster

309 posts in 3948 days


#8 posted 04-10-2021 08:12 PM

Thank you Mads, it sure is.


Lovely setup, really looks like a heart of a shop.
Best thoughts,
Mads

- mafe


View woodbutcherbynight's profile

woodbutcherbynight

9261 posts in 3496 days


#9 posted 04-10-2021 08:12 PM

Beautiful and very functional looking build. Nice work!!

-- Live to tell the stories, they sound better that way.

View pottz's profile

pottz

16954 posts in 2071 days


#10 posted 04-10-2021 11:49 PM

man thats a nice setup for anyone with limited space,well done.

-- working with my hands is a joy,it gives me a sense of fulfillment,somthing so many seek and so few find.-SAM MALOOF.

View crowie's profile

crowie

4593 posts in 3037 days


#11 posted 04-11-2021 12:31 AM

Wish I had the room and level floor to do something similar, well done sir!

-- Lifes good, Enjoy each new day...... Cheers from "On Top DownUnder" Crowie

View SplashMaster's profile

SplashMaster

309 posts in 3948 days


#12 posted 04-11-2021 12:49 AM

Ah a level floor would be nice, there is always one wheel that needs a wedge kicked under it….


Wish I had the room and level floor to do something similar, well done sir!

- crowie


View LittleBlackDuck's profile

LittleBlackDuck

7076 posts in 1907 days


#13 posted 04-11-2021 10:53 AM

Great “little” extension Splash’... Don’t know about you, but after my “expansions” I no longer consider my contractors saw as a small piddly unit.


Ah a level floor would be nice, there is always one wheel that needs a wedge kicked under it….
- SplashMaster

I normally recommend against rubber rimmed wheels because of their tendency to flatten, however, in this case, a big set may be a benefit… and you will still retain movability, even if it’s hard to initiate the initial movement.
Alternatively, shim in it’s “permanent” position and be prepared to chock when temporarily moved.

-- If your first cut is too short... Take the second cut from the longer end... LBD

View Jim Jakosh's profile

Jim Jakosh

26214 posts in 4192 days


#14 posted 04-11-2021 11:49 AM

That is a “killer” saw/router unit!! Nice design and awesome fence!!

Jim

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

View SplashMaster's profile

SplashMaster

309 posts in 3948 days


#15 posted 04-11-2021 11:55 AM

Thank you LBD, I would agree 100%! Its is nice to be able to make cuts all the way out to 4’ and not have boards falling of the back side anymore.


Great “little” extension Splash ... Don t know about you, but after my “expansions” I no longer consider my contractors saw as a small piddly unit.

Ah a level floor would be nice, there is always one wheel that needs a wedge kicked under it….
- SplashMaster

I normally recommend against rubber rimmed wheels because of their tendency to flatten, however, in this case, a big set may be a benefit… and you will still retain movability, even if it s hard to initiate the initial movement.
Alternatively, shim in it s “permanent” position and be prepared to chock when temporarily moved.

- LittleBlackDuck


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