Builing a Work Bench With Integrated Table Saw (DeWalt DWE7492)

[Music] hi and welcome back to the spare time shop I'm Reuben and I've been working in this space for about a year now and up until now that was mostly from the floor or some saw horses but I recently purchased this small table saw and I'd like to make things more organized so I'm planning on building a big worktable with the new table saw [Music] integrated the workbench is entirely made up out of plywood sheets and wood beams now let's start with taking those and cutting them to length to create table [Music] [Applause] legs all right now I got the legs cut to length and I'm planning to screw them together in an L shape like this to provide more stability in both directions for the table but if I were to screw them together as they are these rounded edges would leave a pretty big seam and I don't really like that so I'm going to cut one end of each board to remove the rounded edges it's worth noting that this is an unnecessary step I'm just very excited to use this table saw for the first [Music] time [Music] I'm using a lot of wood glue and 120 mil wood screws because these crossed pieces will need to be as strong as possible and not Flex or bend when I put a heavy piece on top of the workbench now let's bring out the plans to make the next step a bit more logical to follow I'm building a torsion box for the top of the workbench let's begin with the size of the box that have these holes a torsion box workbench is basically using a big plywood box instead of a thick slab of solid or laminated wood it greatly reduces the weight of the workbench and by cutting strips for the sides of the Box all the same width the top should stay perfectly flat when [Music] assembled since a torsion box is pretty much an empty box it has a lot of unused space and that's why I'm cutting out these openings in the sides so the Box opens up and I can use the inside for storage now I've seen some other Woodworkers do the same thing and it just makes sense I've made a template to trace the design for the openings and this pill shape is strongly inspired by the workbench design from Ron pul so be sure to go check him out if you don't already know about him I'm cutting out the shapes with a jigsaw but staying close to the line and the jigsaw leaves some blowout on the plywood so to smooth out the edges I'm coming back with a router with a flush trim bit and following the template to make all the shapes exactly the same now this is also an unnecessary step but since I'll be using this workbench a lot I like the edges to be crisp and [Music] straight [Music] and I'm also rounding over all the edges to make sure they are Splinter [Music] free all right now I got all the upright pieces cut and I made the holes in them so it's time to assemble the whole thing so I can make a structure that goes on top of the bottom panel of the torsion [Music] box I'm using a drill guide to help drill the counter sunk holes for the screws because I'm screwing into the end faces of the plywood so there is very little room for error again using wood glue for a strong joint and checking for square on all the [Music] pieces [Music] sh all right now with the core of the torsion box assembled it's time to screw on the bottom panel now you can see the plywood is a bit warped but when screwing this onto the core of the box it should be pulled flat I'm cutting out a hole for the table saw at the back of the panel now the size of the torsion box is just a little bit smaller than a standard plywood sheet so I'm centering the sheet onto the core with just a bit of of overhang on all sides and using the spacer block to make sure it's all the same on each [Music] [Applause] [Music] side after screwing the bottom panel onto the core I'm coming back with a flush trim bit on the router to clean up all the overhanging edges and squaring up the panel in the [Music] process with the bottom panel screwed onto the frame it already feels a lot more sturdy and this is the underside where I left a big hole for the table saw now the next thing to do is fabricate a box so the table saw will sit flush with the top surface it'll make sense in a moment I'm cutting some pieces as sides for the recessed box where the table saw will sit [Music] [Music] into and to mount the bottom panel at the right height I got some spacer pieces that fall just below the table saw top now just to double check yes the table saw will sit proud just a little bit above the workbench top you would want it this way and not the other way around or the pieces that you push through the table saw will hit the workbench top and that would be pretty dangerous [Music] so I centered a plywood top on the base and the next thing I need to do is cut a big hole for the table saw to fit in I also need to cut a big slot across the top so the table saw fence can slide back and forth you can see that the arms of the fence go pretty far back so these will need all the room they can get and by cutting out a slot on the tabletop and cutting out the box walls this should be [Music] plenty I'm not yet screwing the tabletop onto the box I first need to assemble the legs under the box so let's connect the legs to each other and create a solid base for the top to sit on [Music] I'm adding these extra support pieces because I want to add a big shelf into the [Applause] trate and this piece of plywood will sit just above the floor giving me the the most possible extra storage underneath the workbench all right so the base is now finished and it's really sturdy so the only thing left to do now is to take the base put it on the ground and then take the top and put it on the base so uh let's do some heavy [Music] lifting [Music] and you can see now why I didn't screw the top on just yet so now I can easily get into the box to connect it to the base with these big trust head [Music] screws with the Box screwed onto the base I can mount the tabletop now I'm marking where all the upright walls are so I know where to put the [Music] screws all right now with the tabletop installed on the base the whole thing is really strong the only thing left to do now is trim all the excess edges of the top uh sand everything down and then fit the table [Music] [Applause] [Music] saw [Music] the table saw has this handle that I want to cover up so I traced the shape and cut it out of a plywood piece to [Music] fit and with some sanding and a little bit of cleanup the workbench is ready to be [Music] finished I got these retractable cets from Amazon and installing this pretty straightforward you just screw screw them onto the sze of the legs and what's cool about them is that they can be lifted up so the table legs touch the ground and that way the workbench won't move cuz with normal cerss the table always sits on top of its Wheels making it a little bit wobbly so now I've got an easily movable workbench with a lot of room to put my tools to help keep the tabletop clean and there are even some compartments to put the table saw accessories these are empty spaces I was just planning on throwing the accessories from table saw in them but I will still leave them open to fill up with dust so I'm planning on using some scrap pieces and I will build some drawers now these drawers are nothing more than some plywood pieces glued and nail together and I didn't want to add any hardware that sticks out so for the drawer pools I just cut a recess that fits my [Music] hand all right now I've got to be honest and there's actually one mistake I made while building the table and that has everything to do with the dust extraction from the table saw you see I left this big opening right here thinking I would just feed the hose from the vacuum through it to the table saw but the vacuum hose I have is actually smaller than the table saw exhaust so I need to use this adapter piece and while building the workbench I completely forgot about this piece so let me show you it actually sticks out way further than I [Music] thought now I could just go ahead and drill a big hole right here in the back panel of the table just to feed the adapter piece through and let the hose connect to it straight on but that actually would be a little bit of a shame the better solution would be if this adapter piece immediately took a 90° turn to the right then the hose could sit alongside the back panel and I don't have to cut any holes now I'm sure that adapter pieces like that do exist but I don't really want them to ship to me all the way across the globe just for my stupid mistake so I actually measured this one out and 3D modeled and printed one that fits better to the table so as you can see these both have similar outer diameters to fit into the table saw but this one immediately takes a 90° turn and the other end is actually also bigger than my vacuum hose that's because I made it that way to fit this rubber ring now hopefully this rubber ring will help prevent air loss from the vacuum so let's see if this one [Music] fits and because I don't want to crawl underneath the table every time I'm going to connect the vacuum to the table saw I made an extra piece that I'll mount on the inside of the workbench and then I'll connect a short piece of the vacuum hose in between these two adapter pieces now it's worth noting that this should not be an issue if you got a bigger hose on your shop and won't need this adapter [Music] [Applause] [Music] piece [Music] now with a short piece of hose in between the table saw and the side of the table I can now put the vacuum into the side of the table with a nice snug fit the hose has some extra room to flex so it stays connected when turning the saw blade [Music] 45° [Music] I switched out the blade for a finer one to start fresh on some new [Music] projects and I've already built some pretty big projects on this table as you can see it doesn't budge one bit even when I'm standing on [Music] it [Music] and the big worktop doubles as a long outfeed table which is ideal for ripping up long beans like this [Music] one so we're a couple months in and I've been using this workbench a lot lately um I'm pretty happy with it but there's just one thing that I didn't think all the way through and I've noticed it while using it now that's why I usually wait a little with posting these videos until I get to test all the things that I built well that and I'm am pretty slow at editing but uh let me show you what could be improved on this design so if you want to adjust the fence you can turn this no right here and the fence goes back and forth but if you want a wider range of motion you can take this fence apart and mount it again a little bit further along these tracks now to do this you have to open these two levers and as you can see this one is blocked by the tabletop behind it so no matter how far you pull the fence this lever always gets stuck behind the table Edge now there is a simple solution to get to this lever and that's just to lift the whole table saw out of the bench but that would require me to loosen this panel right here cuz the table saw is actually hooked underneath it so I'm just thinking about cutting half a circle out of here so the ledge can open all the way without me disassembling anything I'm marking half a circle where the lever stops and cut it out of the tabletop and to finish the hole I just made I glued the piece of plywood to the inside and routed out the [Music] axis and now the lever can open without lifting up the table [Music] soone after using the workbench for a couple of weeks I quickly decided to make a cross cut sled I'll keep it short as there are plenty good videos on how to build this on YouTube already now you start with screwing together a sled the size is completely up to you and then cutting strips that fit the miter slots perfectly putting them in the tracks and adding some super glue on the top then dropping the sled onto the worktop while using the fence as a guide to make sure the sled and the TR tracks are square and you can screw the tracks in place once everything's all lined up nicely but to be able to push the sled past the blade I did have to Rite out some grooves in the tabletop and these don't have to be too deep just enough for the sliders to pass through and a little side note again if you don't want a Crosscut sled you don't have to do this step although I highly recommend making one cuz it's pretty damn useful so now it's time to make the first cut I'm raising the blade to cut through the bottom panel of this Leed for the very first time and this part is always a little bit exciting all right looking good so far now let's try a little test piece now let's check if it's Square Yep looks good to me we have a working table [Music] sled and that's it the workbench is fully finished and ready to be [Music] used [Music] so overall I'm really happy with this new workbench it has a nice flat tabletop uh a lot of storage underneath and it adds a lot of functionality to an otherwise empty Workshop I always wanted a table saw and now I've got one that's nicely integrated and I can use this one to build Out Future projects and with the retractable costers underneath I can't complain that this thing will be ever in my way I can just push it aside so if you have any questions about this design or how to build this workbench please let me know in the comments below and as always thanks for watching and I'll see you in the next one [Music] bye-bye

Channel: Spare Time Shop

Views: 129,903

Keywords: work table, workbench, work bench, diy, woodworking

Id: gpmepP3vZfU

Length: 23min 43sec (1423 seconds)

Published: Sun Oct 29 2023