Wired Torsion Box

[Veramacor]

Hi all,

I dunno if this is a first or not, but I'm actually starting to build a mobile base WITHOUT having the table saw first.

Ok I'm pretty impatient, but after measuring the distance between the rails of my own BT to be, I figured I could at least start on the torsion box.

After pouring over Sam Conder's maroon mobile base in the Articles section, and making some measurements myself, I felt pretty confident that I could start constructing.

Once I completed the honeycomb pattern for the inside of the torsion box, I noticed that hey, there is a lot of empty space I could use! The 2 1/2 inches of clearance makes for a perfect space to place electrical boxes, wire, and yes electricity.

My mobile is not going to end up having lots of space for tool, and jigs and stuff, but rather its going to allow me to perform dust collection from within the cabinet. I plan on using the table space between the TS and the routing table as a sanding station complete with masonite pegboard and supporting ribs.

Sorry for the quality of the picture, but it basically shows where the BT is going to end up. The outlet on the wall is actually two dedicated circuits, one for BT/router table, and one for the DC. 2 14-2 cables fit just right in 1/2 inch conduit btw. I will be able to 'kick start' (with a wide,flat switch) the dust collector with my right foot, then start sawing/sanding/routing.

Im not too worried about the structural hit I'm taking cutting out slots for the electrical boxes as Sam Conder's design slaps a third sheet of MDF on the base. I'll report any trouble.

Next will be casters and I'll be ready to close it up.

The torsion box up to now has been contstructed using Ye olde circular saw with an insulation backer on the garage floor. Man I cant wait to saw upright!

[Wood_workur]

that is a neat idea!! If I had the space in my (smallish) shop, I would do that. I need a house for my shop vac (a vented house, of corse)

[HarmsWay]

That's a good idea putting the wiring into the base. I'd put solid wood blocks in the corners and lag bolt the casters though. It will be more solid and allow you to replace the casters if need be. On that subject use wheels as big as you can get away with - 4 or 5" anyway. Keep us posted!

Bob

[Veramacor]

Great idea. I was going to seal them up but lag bolts let me do that after the top is on. 3/4 oak squares for blocks and not scrap mdf blocs you suggest?

[HarmsWay]

The torsion box bottom is MDF right? I'd use a couple layers of 3/4" wood scraps. Predrill the wood and put thru-holes in the MDF. You'll never have to worry about the lag bolts pulling out but if it weighs anything near what mine does it will put a lot of sideways force on the bolts. So it would be best if the scraps filled the horizontal space in the corner pockets. Badly worded but does that make sense? Oh and I'd put the casters on before sealing the torsion box top just to make sure everthing stayed in place. You can always take them off if necessary.

Bob

[Veramacor]

Sounds like i need to make a trip to the BORG and get me some casters with lag screws. No problem scrapping up the corner pockets as you said. I'll just use scrap MDF.

Thanks!

[RayintheUK]

Here's how I did mine:



Ray.

[HarmsWay]

Nothing like a good picture to reduce the word count!

Does that mean you've got lock-tite on the nuts? I'm assuming that the space shown is not accessible now. What happens if the casters need replacing?

Bob

[RayintheUK]

Does that mean you've got lock-tite on the nuts? I'm assuming that the space shown is not accessible now. What happens if the casters need replacing?

Bob

The nuts are Nylocks, Bob. You're correct, the nuts are no longer (easily) accessible. The castors are excellent quality - by the time they need replacing, I'll be the wrong side of the grass.

Ray.

[HarmsWay]

Fair enough.

Bob

[rcp612]

Just one more suggestion about the castors. Make sure the swivel castors are on the end YOU want to use to manuver the base. I put mine on the BT3K end and wish that I'd put them on the router end instead. Now I'm thinking about a removable handle of some sort to move it with since I don't want to push on the saw itself. Just my input.

[HarmsWay]

I put swivels at all four corners. I'm sooooo glad. I can push from any direction.

Bob

[Veramacor]

Here are some pictured of the finished wired torsion box...

[HarmsWay]

Looking good!

Bob