My Mobile Base

Collapse
This topic is closed.
X
X
 
  • Time
  • Show
Clear All
new posts
  • yamato72
    Forum Newbie
    • Apr 2009
    • 57
    • Lansing, MI

    #61
    Originally posted by capncarl
    If you are going with a cabinet saw, why not incorporate the router table in one of the cabinet saw wings or outfeed table? You would have lots more table room than with a cabinet mounted router.... your side of the garage is going to be filling up fast when you get rid of the BT and bring in a cabinet saw.
    I may do both. I got a router lift last month and of course the insert is different than my current plate - a tad smaller in one dimension, and a half inch shorter in the other. I have an idea of how to re-make and re-laminate just one subsection of the saw top, but I don't want to do it. Also, after making the planer base I like how much easier the smaller bases are to move around.

    Comment

    • yamato72
      Forum Newbie
      • Apr 2009
      • 57
      • Lansing, MI

      #62
      I started on the router table over the winter and needed some casters so I decided to upgrade the rubber casters on the big saw tables to urethane and then re-use the rubber ones on the router table. I also took the opportunity to relocate the casters underneath the torsion box. Doing so reduced the dip in the table saw base to almost nothing. Made for an odd sight too:


      Click image for larger version

Name:	20200313_iphone_0565.jpg
Views:	220
Size:	197.9 KB
ID:	839341

      Click image for larger version

Name:	20200404_iphone_0610.jpg
Views:	209
Size:	208.9 KB
ID:	839342

      That brings both of the original saw tables up about 4" to my preferred new working height. I already like it better. Router table build pics next.
      Attached Files

      Comment

      • yamato72
        Forum Newbie
        • Apr 2009
        • 57
        • Lansing, MI

        #63
        OK here's the router table build. This is essentially the same dimensions as the planer base, but a mirror of it, and I decided to do storage doors on the left, nested together. It required some careful measuring to make sure that the doors closed together correctly, and I'm really happy with how it turned out.

        Torsion box base build was exactly the same. Here's the face frames going together:

        Click image for larger version

Name:	20200315_iphone_0553.jpg
Views:	300
Size:	124.3 KB
ID:	839613

        Click image for larger version

Name:	20200315_iphone_0556.jpg
Views:	155
Size:	98.2 KB
ID:	839614

        The storage doors will be hinged opposite each other so the outer door, hinged at the back, will close on top of the inner door, hinged at the front. Hopefully you can start to see from these photos how it will work:

        Click image for larger version

Name:	20200315_iphone_0557.jpg
Views:	313
Size:	156.1 KB
ID:	839615
        I started running out of pocket hole real estate and mis-drilled a couple so you can see some oopsies here.

        Click image for larger version

Name:	20200315_iphone_0559.jpg
Views:	171
Size:	101.0 KB
ID:	839616

        Click image for larger version

Name:	20200315_iphone_0561.jpg
Views:	173
Size:	77.3 KB
ID:	839617

        Click image for larger version

Name:	20200315_iphone_0559-1.jpg
Views:	275
Size:	130.1 KB
ID:	839618

        The top is constructed much like the one on my BT and CMS bases, 2 layers of 3/4" MDF wrapped in maple (thought I mitered the corners this time):

        Click image for larger version

Name:	20200322_iphone_0693.jpg
Views:	261
Size:	139.3 KB
ID:	839619

        Click image for larger version

Name:	20200324_iphone_0683.jpg
Views:	245
Size:	165.3 KB
ID:	839620


        Click image for larger version

Name:	20200321_iphone_0700.jpg
Views:	272
Size:	126.4 KB
ID:	839621

        Click image for larger version

Name:	20200321_iphone_0701.jpg
Views:	267
Size:	133.5 KB
ID:	839622

        Click image for larger version

Name:	20200324_iphone_0687.jpg
Views:	270
Size:	96.7 KB
ID:	839623

        Comment

        • yamato72
          Forum Newbie
          • Apr 2009
          • 57
          • Lansing, MI

          #64
          Here's the two cabinets together:

          Click image for larger version

Name:	20200324_iphone_0689.jpg
Views:	326
Size:	120.9 KB
ID:	839625

          Now to chop up the top for the router insert, using essentially the same procedure as when I added the router insert to my BT table top at the beginning of this thread (still just as nerve-wracking):

          Click image for larger version

Name:	20200329_iphone_0619.jpg
Views:	257
Size:	103.2 KB
ID:	839626

          Click image for larger version

Name:	20200329_iphone_0620.jpg
Views:	263
Size:	138.7 KB
ID:	839627

          The rabbet (on account of the way I chose to route it) required a 1-1/2" straight bit. It was a monster.

          Click image for larger version

Name:	20200329_iphone_0617.jpg
Views:	248
Size:	121.5 KB
ID:	839628

          Click image for larger version

Name:	20200329_iphone_0624.jpg
Views:	257
Size:	111.8 KB
ID:	839629
          This came out great. And some more chopping for the miter slot:

          Click image for larger version

Name:	20200329_iphone_0622.jpg
Views:	243
Size:	157.7 KB
ID:	839630

          Click image for larger version

Name:	20200331_iphone_0615.jpg
Views:	163
Size:	111.3 KB
ID:	839631

          Now for the door construction, which is basically like building drawer boxes but with mitered corners:

          Click image for larger version

Name:	20200409_iphone_0581.jpg
Views:	249
Size:	125.3 KB
ID:	839632

          (I reinforced the corners with biscuits)

          Click image for larger version

Name:	20200409_iphone_0583.jpg
Views:	174
Size:	93.5 KB
ID:	839633

          Click image for larger version

Name:	20200404_iphone_0614.jpg
Views:	162
Size:	86.6 KB
ID:	839634

          I decided to use french cleats to give me some storage flexibility. The cleats were ripped out of 1/4" MDO maple to help stick with the same materials as the rest of the cabinet:

          Click image for larger version

Name:	20200408_iphone_0599.jpg
Views:	258
Size:	103.4 KB
ID:	839635

          You can also see that I've installed the piano hinges for each door

          Click image for larger version

Name:	20200408_iphone_0596.jpg
Views:	246
Size:	119.5 KB
ID:	839636

          Comment

          • yamato72
            Forum Newbie
            • Apr 2009
            • 57
            • Lansing, MI

            #65
            I'll interrupt the construction narrative for some major surgery on the BT. It would not turn on and, as suspected, carbon build-up was keeping one of the brushes from seating properly. Cleaned it out and it's been fine ever since (I wish I could say the same for the elevation rack).

            Click image for larger version

Name:	20200411_iphone_0575.jpg
Views:	235
Size:	90.6 KB
ID:	839638

            Click image for larger version

Name:	20200411_iphone_0576.jpg
Views:	170
Size:	121.8 KB
ID:	839639

            So here are the cabinet doors installed. The inner door is held in the closed position using rare earth magnets epoxied flush with the outer edge. I will use a mechanical latch or clasp for the outer door. I haven't decided yet what style to use.

            Click image for larger version

Name:	20200409_iphone_0589.jpg
Views:	271
Size:	130.5 KB
ID:	839640

            Click image for larger version

Name:	20200409_iphone_0588.jpg
Views:	268
Size:	134.4 KB
ID:	839641

            And here's the first batch of storage "units" after spending a day or so trying different construction methods

            Click image for larger version

Name:	20200419_iphone_0558.jpg
Views:	172
Size:	92.7 KB
ID:	839642

            The plan is to store drill bits and saw blades of all types in this cabinet:

            Click image for larger version

Name:	20200420_iphone_0553.jpg
Views:	258
Size:	161.8 KB
ID:	839643

            DC port on the back. This is from Rockler:

            Click image for larger version

Name:	20200427_iphone_0558.jpg
Views:	267
Size:	113.2 KB
ID:	839644

            And now chopping the top up again for t-track. I did not have a 7/8" router bit so I had to create a template and use a bottom- bearing router bit. Really, really nerve-wracking:

            Click image for larger version

Name:	20200428_iphone_0553.jpg
Views:	252
Size:	193.9 KB
ID:	839645

            After debating for a while, I elected to leave the radius at the tend of the t-track slots, and used the miter saw and a hand file to make the matching radius in the track:

            Click image for larger version

Name:	20200428_iphone_0557.jpg
Views:	284
Size:	136.4 KB
ID:	839646

            Click image for larger version

Name:	20200427_iphone_0560.jpg
Views:	262
Size:	174.3 KB
ID:	839647

            Routing for the t-track worked well except for some avoidable tear-out in the maple banding. Another oopsie. Epoxying everything into place:

            Click image for larger version

Name:	20200428_iphone_0556.jpg
Views:	254
Size:	172.0 KB
ID:	839648

            Adding the WOOD Magazine router fence that I started, oh, 6-7 years ago:

            Click image for larger version

Name:	20200512_iphone_0585.jpg
Views:	169
Size:	85.3 KB
ID:	839649

            Click image for larger version

Name:	20200512_iphone_0584.jpg
Views:	159
Size:	102.4 KB
ID:	839650

            And, lastly, a new safety switch:

            Click image for larger version

Name:	20200516_iphone_0579.jpg
Views:	173
Size:	94.1 KB
ID:	839651

            That's it for now. I'm shopping hard for a used cabinet saw and have been considering how to construct a mobile base for a larger, heavier saw that will still use the DNA of the bases and cabinets that I've built in this thread. I will post further once I have made some progress with that.

            Comment

            • twistsol
              Veteran Member
              • Dec 2002
              • 2893
              • Cottage Grove, MN, USA.
              • Ridgid R4512, 2x ShopSmith Mark V 520, 1951 Shopsmith 10ER

              #66
              I am impressed. The router table looks fantastic and I love your attention to detail. You obviously put a lot of thought into the design.
              Chr's
              __________
              An ethical man knows the right thing to do.
              A moral man does it.

              Comment

              • Pappy
                The Full Monte
                • Dec 2002
                • 10453
                • San Marcos, TX, USA.
                • BT3000 (x2)

                #67
                How well does the dust collection on the fence work? Do you have plans to the fence? I have a slightly modified version of the NYW router table and I'm not happy with the fence.

                edit: I just saw that it is from Wood magazine plans. I'll have to dig through my stack and see if I have the right issue.
                Last edited by Pappy; 06-11-2020, 01:37 PM.
                Don, aka Pappy,

                Wise men talk because they have something to say,
                Fools because they have to say something.
                Plato

                Comment

                • yamato72
                  Forum Newbie
                  • Apr 2009
                  • 57
                  • Lansing, MI

                  #68
                  Originally posted by Pappy
                  How well does the dust collection on the fence work? Do you have plans to the fence?
                  I have the jointing fence installed in that photo and have only tried jointing a couple edges so far. The movable faces allow you to create really good airflow (louder than the router actually using my shop vac) so, so far, so good. Eventually I'll make a drawer and door for the cabinet and I plan to have some holes in the door to aid in airflow. The 4" dust port won't be used though until I get a real DC.

                  I started and left the fence unfinished years ago (first bought the plans in 2009) and this was my excuse to finally finish making the faces and doing final assembly.

                  Comment

                  • yamato72
                    Forum Newbie
                    • Apr 2009
                    • 57
                    • Lansing, MI

                    #69
                    Well gents this weekend I finally acquired and brought home an "old iron" cabinet saw so I'm nearing the end of my time with the BT (11 years with the BT3100 and another decade or so before that with my dad's BT3000).

                    My BT's final project will be building a mobile base for the "new" saw. It's going to be a torsion box like the last two, but it will be a bit more complex because I'll need to accommodate the fixed 34-1/2" height of the saw, bring it up to my preferred working height of about 41", and still match the aesthetic of my other mobile bases. I am not making a 6-foot-long monster this time. The base will be about 30" X 28". It may require outboard leveling feet. I'll make some type of separate mobile stand to support the end of the fence rails. I'll post pics here as I make progress.

                    randombetrayal, I sent you a PM to see if you are interested in the saw and mobile base since you are local.

                    I'm hoping to find a good home for these this summer and I hope they go to someone from the BT community, even if the saw itself would be for parts on account of the problem with the elevation adjustment.
                    Last edited by yamato72; 06-15-2020, 01:24 PM.

                    Comment

                    • yamato72
                      Forum Newbie
                      • Apr 2009
                      • 57
                      • Lansing, MI

                      #70
                      Here's the plan I came up with to hold a 400lb+ saw:

                      Click image for larger version

Name:	pm66_base.jpg
Views:	155
Size:	120.6 KB
ID:	839754

                      The torsion box can only be about 2-1/2" high in order to keep the saw table at my 41-1/4" working height. The sides remain 4-1/2" tall just like my other bases, and I routed out the top to achieve the "look" I was going for. To compensate for the shorter torsion box, I added 4" tall ribs across the bottom. Everything is registered using 1/4" dados. Here is the underside of the bottom skin showing the stopped dados for the bottom ribs:

                      Click image for larger version

Name:	IMG_8131.jpg
Views:	116
Size:	95.6 KB
ID:	839755

                      Next the dados and rabbets cut for the bottom and "middle" (shelf? platform?) skins. Both were rabbeted in order to line up the dados precisely, then I'll cut off the rabbets on the middle skin in order for it to fit down inside (hope the pics help this make sense):

                      Click image for larger version

Name:	IMG_8132.jpg
Views:	115
Size:	104.4 KB
ID:	839756

                      The the top and middle skins were dadoed for some addtional braces:

                      Click image for larger version

Name:	IMG_8133.jpg
Views:	121
Size:	92.4 KB
ID:	839757

                      Then I cut and assembled the ribs and also installed the T-nuts for the casters:

                      Click image for larger version

Name:	IMG_8140.jpg
Views:	115
Size:	112.5 KB
ID:	839758

                      Here's the middle skin in place:

                      Click image for larger version

Name:	IMG_8142.jpg
Views:	111
Size:	109.3 KB
ID:	839759

                      Comment

                      • yamato72
                        Forum Newbie
                        • Apr 2009
                        • 57
                        • Lansing, MI

                        #71
                        OK on to the rest of the assembly. Here the first two sides and the two top ribs/braces are getting glued up:

                        Click image for larger version

Name:	IMG_8145.jpg
Views:	133
Size:	114.5 KB
ID:	839761

                        And here the remaining sides have been glued in place and the top skin is ready to go on:

                        Click image for larger version

Name:	IMG_8148.jpg
Views:	109
Size:	102.8 KB
ID:	839762

                        Top skin glued down and I think I've sanded the sides at this point

                        Click image for larger version

Name:	IMG_8149.jpg
Views:	125
Size:	107.8 KB
ID:	839763

                        Now I'm routing the cut-out for the saw cabinet to sit down into. I used a 4-1/2" hole saw to form the radius in a template made out of 5mm birch ply, and routed it out with a bearing bit. The straight parts were done with just a straightedge. This was a bit too much of a job for my poor trim router, though.

                        Click image for larger version

Name:	IMG_8151.jpg
Views:	116
Size:	109.2 KB
ID:	839764

                        Click image for larger version

Name:	IMG_8154.jpg
Views:	120
Size:	147.9 KB
ID:	839765

                        Lastly I glued the ribs into the dados in the underside of the bottom skin, and installed the casters:

                        Click image for larger version

Name:	IMG_8156.jpg
Views:	115
Size:	132.2 KB
ID:	839766

                        Click image for larger version

Name:	IMG_8157.jpg
Views:	108
Size:	108.8 KB
ID:	839767

                        Finished product:

                        Click image for larger version

Name:	IMG_8158.jpg
Views:	111
Size:	76.7 KB
ID:	839768

                        Comment

                        Working...