Table saw Bench for DeWalt DWE 7485 HD 1080p

hi my name is terry welcome back to my workshop um i've had a number of people ask me how i built this table saw bench um how i inserted a table saw and is there any plans basically there isn't any plans i don't really make plans i sort of i do sometimes but i sort of make ups to go along now when i built this i completely forgot to video it i was in the zone at the time and i just cracked on and got done but i did take a number of photos why didn't video i do not know but i've got quite a few photos showing how it went together so this video is going to be slightly different in as much as it won't be a video it'll be more like a slideshow or a collage of photos showing how it's built but hopefully you'll get an idea of everything together so i'll show you those in a second uh before i do that a few people have asked me sizes so let me give you some measurements and you take measurement holder just here the bench is 64 inches long or 162 centimeters the width is 37.5 inches or 95 centimeters the height including the casters is 35 inches or 88 centimeters so don't forget that does include four inch coat of coast but four inch coasters which are mounted at the bottom as you can see it fits quite nicely i'll turn the bench around so you can see it moves really easily as you can see the saw is designed to fit exact which is exactly what i wanted um all about this strip along the back which you need because if you only saw you'll know goes all the way across up to the side blade that'll work out so you need this insert the back for it to run along the rack and pinion that's fitted at both ends of the saw as you can see that works quite well lock into place as you know i've got a number of other features on to this as well silly silly little things pencil holder simply made out of some pvc tubing always managed to have a pencil right next to the saw on the other side got a really handy tape measure holder it's a little holder the miter gauge which i very rarely use because as you all know i made a crosscut sled for my saw handy screwdriver again it fits on the magnet and that's just purely there for the purpose of this the rest of the bench as you can see i mainly use for storage small materials [Music] really simple and it acts really good as you can see storing your clamps your small clamps anyway and i've got some larger clamps still just there works really really well okay so let me move on and show you how i put it together right let's get started it's time to remove the old titan table saw this is easy to remove because it was simply bolted down with four bolts as you can probably see with that now out the way we have an empty space as you can see the shelf is already there this may not necessarily be at the right height but that's an easy fix but first things first i want to fix a new top so tons of wood glue as you can see and i'm going to cover this with a brand new sheet of 18 mil ply as you can see i've clamped this all the way around i did put some weight in the middle as well but there's no photographs without unfortunately i actually left this for two days to dry i placed the saw roughly where i wanted to go but now it's time to get some exact measurements i took the table saw measurements and made sure that the table saw sat central to the bench now i decided to put down some masking tape so should i get the measurements wrong i can rip it up and start again now onto the brave part time to start sawing i always prefer to use a handsaw when i'm cutting anything like this well that went surprisingly well you will notice in the picture in a second that i've had to cut right away across on the right hand side that allows for the rack and pinion mechanism on the saw now you can't see it very well in this photograph but once i'd cut out the hole at the narrowest point of the table top if that makes sense i was then able to drop the table into the hole and the outer wings acted as a template i drew round nose with a pencil removed the saw and then cut out the shape using a coping saw i then tied it up the cuts with the electric sander now i've just remembered why i cut this straight on the right hand side it's so you can get to the locking mechanism on the fence when the fence is in position you want to lock it down there's a lever on the right hand side of this saw for those of you that own this saw you'll know exactly what i'm talking about and you need to be able to get to that lever i then decided to put a nice chunky edge in all the way around the bench this was two they've been playing down a little bit through the thicknesser this is thicker than it needed to be but it was done on purpose because i wanted to put an engine all the way around and that acts as a shelf for the edging i now need to think about tidying up these edges but first of all let's drop the saw in so the saw fits perfectly i'm really happy with the results and as you can see in the next couple of pictures i've tidied up the front edges as well you may notice that i had to router in a tiny groove just along those two front edges that allows for the rack and pinion to run smoothly i then removed the saw and fitted some mounting blocks to hold the legs of the saw in place so the saw doesn't move around it was then time to remount my vise that was easier said than done because now the plywood was doubled thickness so device went back in a different place but that was an easy fix so the device now back in place it was time to move on to the sides i had previously countersunk these holes using a 10 mil drill bit this allowed me to cut some dowels at about half inch long glue and hammer into the holes then once the glue has dried i cut these off with a flush cut saw and give them a good sanding back with the sander this normally produces quite a nice result as you can see these next pictures show the grooves i had to route around to allow for the mechanism of the rack and pinion at the front of the saw and again at the back of the saw i then attached the cross member along the front this is attached to the shelf the reason for this it was so that i could adjust the shelf up and down once it was right i then put two screws either side and screwed those into the legs as you can see the next few pictures just show the finished item i'm really pleased with the way this turned out this is actually proved to be a really useful tool um and gets used not quite daily because i'm only a weekend sort of hobbyist but i use it all the time i'm now going to show some features and benefits of the saw starting off with how i fixed the table saw into the bench in case you're wondering what holds the saw in place i've cut two little pieces of plastic and mine is screwed down into my bench as you can see there's already two little holes there's already two little holes built into the saw as you all know if you already own this saw and i'm sure that's what they're for come around to the i've also got as you can see two pieces of timber to stop it from moving that's also should i take the saw out at any point when it goes back in i know it's going back in exactly the same position providing the screws at the front line up this is quite handy as well i've also put a little table um table a cable tie rack onto there as well which works quite well on the underside i have a cut out ready for dust extraction now a can vac with two and a half inch hose for those of you not familiar with the cam back it's one of those or one of those this is a double motor um version which is slightly bigger at 55 liters as well now that's got a two and a half inch hose that comes out of that and that fits absolutely perfectly as you can see you couldn't wish for a better fit you can see the wings on the left-hand side fit quite closely and are all part of the bench a lot of people thought they were separate they're not as i say the cutout along the back has to be there to allow for the rack and pinion to slide freely and that goes right away to the end and stops with a quarter of an inch to spare okay this could do it tidying up i guess there's not really much need now the beauty of this bench is it's double thick because i already had a bench here and i already had 18 mil ply so with another layer of 18 mil ply this is now sitting at 36 mil so it's really really sturdy and i know it's completely flat as you can see i fitted this with four inch lockable casters i started off with three inch but they were nowhere near strong enough so i moved those over to my miter saw bench so as you can see the three-inch casters now live on my mitre saw station this is perfect because i never moved to mitosaur station that stays against the wall permanently there is a video on the build of this as well if you're interested now the legs on this are pretty sturdy i didn't want this bench to have much movement at all so it might be over the top but it's made with what we better know as four befores just like this they're not exactly four before as you know they're pretty damn close they're nice and strong the top although you can't see it from here underneath is five by one i've then gone around that afterwards with fibre two as you can see and on the front on the front i had to router out these recesses again to allow for the rack and pinion which hopefully you can see the bottom of the bench is freeba one and then the bench has two cross monitors that run across on both sides and is then strengthened again with 18 mil ply at both ends that gives it plenty of strength that makes the bench really nice and rigid underneath you will see as three cross members and then again another real strong piece of ply which helps hold the saw in place and holds the table that actually holds the saw again making it nice and strong cross cut lid as you all know it fits in just here now it has gone a little bit stiff um so what it tends to do every now and then there's a little bit of machine wax you can buy this anywhere um i tend to get this one it comes from max minster it's very good tiny little bit of blue roll and it really doesn't need much at all there's a rub down each side and you'll see that's the difference and it's just a quick walk around so you can see the bench from all angles okay so that's pretty much wrapped up this video stroke photo collage if you like um i'm hoping that gives you um all the people that have asked me an idea of how i put the bench together again thank you for watching and i'll see you in the next video

Channel: TerryTheMaker

Views: 185,260

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Id: XfyideUaDnE

Length: 15min 51sec (951 seconds)

Published: Sat Jan 01 2022