Table Saw Work Station

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Project by bigpops0259 posted 01-04-2008 06:25 PM 9878 views 7 times favorited 11 comments Add to Favorites Watch

My shop is a 24’ x 32’ garage, fully update to handle a wood shop with controlled heat, alarm, smoke and fire signal to the house. A few years ago I wanted to confine and utilize my saw work area to its potential. I purchased PVC sheet, it was massive at 1 7/8’ thick 4’ wide 8’ long(deep gray). I want a new run out work area at my table saw and a few jigs. I thought this material would be perfect, very dense, very heavy, very easy to mill. I added a 42’ x 80” piece to my Unisaw. I made a new laminate extension (white) that I made a router table/lift with a Jet/Jessem lift, and a few Incra jig glides(Red/gold). I made new fence guards saw/router. I used a P&C 7539 3 1/4 hp Router with a Jacobs quick release collet in the lift(change bit with a snap and without removing the router or lift). I added an Excalibur sliding panel cutting table(Black). I also made a cove cutting jig, don’t know where I seen this jig at or if I did. It was about three years ago. It’s a great way to make cove molding, set angle set blade height (at increments) and push through, pretty easy. I will say that using 8” wobble dado cuts the cove the easiest, I tried different blades. I didn’t try my stack dado thou. I was just at Rockler in Cleveland and saw that they make a particle board/laminate model of this jig. I added a Grizzly 3 hp central vacuum system, connecting it to all my machines with PVC pipe and Aluminum blast gates, some PVC fitting I had to turn on my Lathe to fit smaller Diameter fittings on blast gates. and last a REMOTE CONTROL vacuum switch. I made a steel sheet metal vaccum box to surround the under mounted router, with fence vacuum almost no dust escapes. Makes a great work assembly area. The PVC clean up easily, glue, stain, varnish, repair with JB weld and sand. I still have a phone number for the guy I bought the PVC from if interested.

-- Marty Ohio

11 comments so far

View David's profile


1969 posts in 5262 days

#1 posted 01-04-2008 06:29 PM


Well there are going to be some guys drooling over this set-up. Very nice. Looks very functional. How expensive was a sheet of PVC that size?


View bigpops0259's profile


323 posts in 5272 days

#2 posted 01-04-2008 06:32 PM

I bought two sheets, one stated, and 1- 48×48 x 1 1/4 for 125.00

-- Marty Ohio

View TreeBones's profile


1828 posts in 5146 days

#3 posted 01-04-2008 08:24 PM

I agree with David, wish I had more room.

-- Ron, Twain Harte, Ca. Portable on site Sawmill Service

View rikkor's profile


11295 posts in 4997 days

#4 posted 01-04-2008 08:32 PM

I’m with bones, I’d love it, but I just don’t have the space.

View CharlieM1958's profile


16292 posts in 5341 days

#5 posted 01-04-2008 09:06 PM

Drooling here! Too bad I don’t have the space or the bucks.

I believe the technichal name for that setup is “big-a** workspace”.

-- Charlie M. "Woodworking - patience = firewood"

View motthunter's profile


2141 posts in 4922 days

#6 posted 01-04-2008 09:15 PM

Nice to see such great work from another Ohio guy. I have looked at your projects and I have to compliment your skills.

-- making sawdust....

View Bob A in NJ's profile

Bob A in NJ

1351 posts in 5122 days

#7 posted 01-05-2008 06:15 AM

Very nice setup, I too am short on space working in a two car garage. Everything is on wheels and I feel like a weight-lifter as I have to position everything in place, then return it against the walls in order to fit the cars in during winter.

The cove cutting set up is great. I happen to be doing the same this week. I ‘m working on 2 new Hope Chests for my daughters and decided to make bracket feet cut with this type of set-up. I agree they are easy to make but look complcated and very nice. Here is the link to the plans I used.

-- Bob A in NJ

View clint's profile


10 posts in 4662 days

#8 posted 09-17-2008 06:33 AM

fantastic work really like the router add on do you have any plans for the cove cutting jig you made or a cutlist pretty awesome jig. thanx

View Beginningwoodworker's profile


13345 posts in 4796 days

#9 posted 12-04-2008 06:45 AM

Nice table saw set up.

View Stanley Coker's profile

Stanley Coker

269 posts in 4318 days

#10 posted 09-14-2009 12:18 PM

Very nice set-up. I woud like to have the number of the guy that you got the PVC if you don’t care.
Again very nice.

-- Stanley, North Georgia

View kz5rt2's profile


5 posts in 4291 days

#11 posted 09-22-2009 03:00 PM

Wow, very impressive

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