Woodworker's Journal 2007-Winter, страница 65


to get it right), remove the sticks one at a time and press the laminate in place. Use a roller to ensure complete contact, then trim the edges with a bearing-guided chamfering bit chucked in a portable router (see Figure 4). Stick some masking tape to the laminate so you can write on it, and locate the saw on the station's top.

Mark the locations of the bolt holes, remove the drawer so you don't hit it with an errant drill bit, and bore holes for appropriately sized bolts. Secure the saw to the station with bolts, washers and nuts.

Making the Legs

Before attaching the two outfeed wings to the saw, you need to install their adjustable legs. Begin by ripping and jointing the housings (pieces 33) to size, then plow a 1/4" square groove in the inside face of each. The spacers (pieces 34) are just cut to length, then a 1/4" square tongue is milled on each of the long edges. Glue and clamp a pair of housings to each spacer and, when the glue is dry, attach a hinge base (piece 35) to each of these subassemblies. This is done with a biscuit, glue and a pair of pre-bored, countersunk 2" screws.

The legs (piece 36) begin life as a simple molding that is just a piece of stock ripped and jointed to size, with 1/4" removed from each long

edge (see Figure 5). Crosscut them to length, then sand each so it slides freely in its housing.

To make the legs adjustable, each is slotted (see the Exploded View Drawing, page 62). Cut these slots on the router table with a 1/4" up-spiral bit, in several deepening passes.

On the drill press, bore a 1/4" hole through each housing about 3" up from the bottom. Slide each leg into its housing, put a lock washer and a flat washer on a bolt (piece 37 through 39), and slide the bolt through the hole in the housing subassembly. Thread it through the slot in the leg and out the other side, then slide on a flat washer, a lock washer and a wing nut (piece 40).

Wrapping Up with Dust Collection

If you have a mid-sized shop vacuum, it should fit nicely in this cabinet. Drill a 3" clearance hole in the saw station top for the vacuum hose.

Attach the wings to the cabinet with brass piano hinges. Then apply the finish of your choice. For the shop, we used a natural Danish oil finish that can easily be renewed as needed.

With that done, you're ready to start looking for a new project, preferably one that requires a whole lot of miter cuts! A _/

Winter 2007

Figure 4: After applying the laminate, trim it with a bearing-guided chamfer bit. Creating this 1/8" chamfer will eliminate sharp edges.

Figure 5: The two drop-down legs that support the outfeed tables are made from a simple molding milled on the table saw.

The portable rollers can be attached anywhere along the length of the wings and store in the drawer when you're done.


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