Picture of Table Saw Station
I have always wanted a good quality cabinet makers table saw but dont want to fork out the cash to purchase one.  I have made due with my small contractors saw for the last few years and decided now is a good time to retrofit this small saw.  I plan to build a large frame around this existing table to increase its ability to cut larger sheet goods, and also give it a mounting system for a proper biesemeyer fence.

The whole build from start to finish has been documented with both video and pictures.  Enjoy!

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Step 1: Subframe

Picture of Subframe
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The start of the saw station is with the build up of the subframe.  The entire subframe is built up from 2x4 lumber.  It its important when designing to take into account the actual dimensions of the lumber you are using.  For the most part a 2x4 stud will actually measure ~0.5" shorter in both axis.  You can also get variances in sized depending on the drying process (not all of my 2x4 lumber was from the same batch, and as such there is differences in size...all easily designed around so long as you expect it).

A square will make your life MUCH easier when building big boxes like this.  Cheap adjustable squares are usually just that, cheap and not square.  A set of machinist squares are the best but the next best thing at a fraction of the cost are 1 piece framing squares.  Even the cheap ones seem to hold a good tolerance thru their length.

choffman158 months ago
Awesome build man. Its a real inspiration to ehat I envision. Thanks
My build, thanks for the inspiration
wrsexton1 year ago
Now you're a couple years down the road, any updates or insights for fine tuning this great project?
Confounded Machine (author)  wrsexton1 year ago
Many thanks! In actuality I have changed nothing since I built it a few years back. I've clamped a board to the back now and then to keep the sawdust from flying out my garage door in the summer but other then that it has been working exactly as pictured. I have not even had to adjust the fence once in the time since I built it so I'm very happy with the outcome.
JimHTP1 year ago
That fence system is really good, would you consider doing a full instructable on just that portion with more detail?
Machine3 years ago
That's a nice bench. Well made, looks good, all the corners look 90 degrees. Everything looks straight, smooth.

Wish I could build a bench like that.

It's so good you might consider publishing the plans for a fee.
Confounded Machine (author)  Machine3 years ago
Thankyou for your kind words...the plans are far to simple to offer at a fee tho, I will upload the file to the warehouse and post a link along with the introduction video for anyone that wants a closer look at the rough outline.
Did you ever getting around to doing that? If so could you post a link please?

Great work BTW particularly with the fence.
Really exhaustively detailed. Excellent work. i had never even considered beefing up my contractor saw, although I had done a little research on after-market fences. Thanks for shifting my perspective!
Thanks! I had shot far more video then I posted but the invention of wireless networked smart phones really makes documenting/editing process much easier.

I'm glad I was able to shift your thoughts more towards the "make" end of the spectrum :) .

Confounded Machine (author) 3 years ago
Now with the saw complete this is the first project I made with it (actually I made a cross cut sled first, then used that to help build this puzzle).  The rip cuts would have been a bear with my old fence but is simple as pie with the new behemoth!

rickharris3 years ago
You should have a top guard over the blade and a riving knife behind the blade for safety reasons to stop material riding over the top of the blade and getting thrown back at you. Even with these items this still happens and can/does hurt - I know!

Other than that a neat build
this saw clearly came with those items and this person feels comfortable enough to not use them. free will is a great thing.
If it did they should go back on.

It's so often the case that people through inexperience, not having any problems in the past not having the reasons explained don't fit safety articles.

I have had a table saw, a large one, throw things at the operator even with these safety features so I feel obliged to tell users what is correct.

Indeed free will is a valuable thing, in general, ignorance isn't.
Confounded Machine (author)  rickharris3 years ago
Thanks for the comments. I do agree a "proper" riving knife is a good thing for safety (the one on this saw was poor stamped steel that was causing more harm then good).

Blade guards are a fickle conversation topic (ask any experienced wood worker and I'll bet you'll get a whole spectrum of answers). I feel more comfortable without but thats my choice.

seamster3 years ago
I'm in the process of purchasing my first table saw right now, and this has given me some great ideas. Thanks!
Confounded Machine (author)  seamster3 years ago
I'm glad I was able to get your mind churning.
dimmaz883 years ago
Awesome project. Simple and effective.
I'll have to make one similar when I have the room!

Keep up the good work.
blkhawk3 years ago
Great job! I thought about doing something similar. I find myself cutting large sheets of plywood and this will work perfectly for that purpose.