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stable when set in place, I planned to add levelers to the corners of the base. This means you'll need access to*the levelers to adjust them. For this purpose, I drilled access holes in the router table case and the left storage case (and later the base).
Now, the cases are ready for glue and clamps. And once the assembly is completed, all the outside edges of the cases are rounded over.
Table Saw Case. I had one requirement for the table saw case that made building it a bit more involved — dust collection. Figure 4 at right shows how it works. As you can see, the top of the case has a large cutout. 1 did this by drilling holes at the comers and then removing the waste with a jig saw.
Divider. Below the cutout, an angled divider funnels the dust to the back of the case. It's held in place by a pair of angled cleats.
It works best to add the divider after the case is assembled. First, cut the parts to size and then screw the cleats and the divider together, Then you can slide the assembly into the case from the front, and fasten it in place from above.
Finally, rather than cut a dust port directly into the back panel, I opted for a large cutout, covered with a separate dust port panel. This will give you better access to the dust chamber when needed.
The Base. Once all four cases are complete, you can build the base that connects them. Like the cases, it's pretty basic, but there's one point I should mention up front. The base is sized to hold the four cases and the end panels that support the top, along with the overlay doors and drawers. When everything is in place, the goal is an even %" reveal all the way around.
You start the base by building a sturdy frame from "ripped down" two-by stock (Figure 5). The only detail you'll need to worry about is a saw kerf running around the inside perimeter. This gives extra support to the levelers you'll add (Figure 5a). I relied on woodscrews to assemble the frame.
SIDE VIEW (FRONT)
DUST PORT PANEL
x 114 -
#3 x W Fh x WOODSCREW
TABLE SAW CASE DIVIDER
SIDE VIEW (BACK)
TABLE SAW CASE SIDE
~CENTERED 4"-DIA. HOLE FOR DUST COLLECTOR
TABLESAW CASE BOTTOM
(17% x 21)
TABLE SAW CASE BACK
(1714 x 1714)
NOTE: JOINERY is IDENTICAL TO STORAGE AND ROUTER CASES
NOTE: ROUT 3/,6" ROUNDOVER ON ALL EDGES AFTER ASSEMBLY
DUST FORT PANEL
(10 x 12)
FLANGE OF LEVELER FITS INTO SAW KERF
BASE FRAME SIDE
(3 x 60)
NOTE: CUT KERF FOR LEVELERS BEFORE ASSEMBLY
BASE SKIRT END
(3% x 21)
BASE FRAME RAIL
(5 x 16)
Once the frame is assembled, you can wrap it with an MDF skirt and top. The skirt pieces are butted at the corners and the top is cut to fit inside the skirt. With this done, I drilled an adjustment hole in each corner and then installed the levelers. Finally, I routed a roundover on the top edges and the corners.
Put It All Together. Now you're ready to screw all the cases and the
base into one assembly. And here, you just want to make sure you get everything aligned properly First, I set the cases in place on the base and fastened them together. The four cases should be flush across the front (this will be the side of the router table case). Now, when you fasten the cases to the base, simply leave an even, 1 %" setback on each end and across the front.
BUTT JOINT AT CORNERS
BASE FRAME MADE FROM "TWO-BY' STOCK
SKIRT PIECES AND TOP GLUED TO FRAME