Table-Saw-Workbench-Building-Plan Remodelaholic 24sept19

DIY TABLE SAW WORKBENCH
WITH ROCKLER T-TRACK SYSTEM
courtesy of Remodelaholic.com
Find the original photo tutorial and additional info at

www.remodelaholic.com/table-saw-workbench-building-plans-rockler-t-track-system
These instructions are provided for entertainment purposes only. Please consult a professional if you are attempting any projects of which you are unsure. Take all safety
precautions when using power tools or other dangerous objects and read the instruction manuals before using any device of which you are unsure. Remodelaholic is not
responsible for any injury or damage sustained while attempting to duplicate projects or tutorials. All projects are done at your own risk.
©Remodelaholic.com – Visit us at www.remodelaholic.com for more FREE building plans and budget-friendly DIY tutorials
Table Saw Workbench with T-Track System - page 2 of 9 Free building plan courtesy of Remodelaholic.com
PLAN DIMENSIONS
Top View
Front View
Side View
TOOLS LIST
 Table saw  Router for T-Track tracks  Brush for polyurethane
 Circular saw  Power chord  Rags for dusting
 Plywood circular saw blade  3/4″ diameter router bit  Pencil
 Jig saw  Sockets for lag bolts  Tape measure
 Miter Saw  Sander
 Drill  Sand paper 120 and 150
WORKBENCH MATERIALS LIST *contains commissioned affiliate links for your online shopping convenience
Be sure to use cabinet grade plywood or better quality for flatness and select all your wood that is as straight as possible.
 (4) Sheets of Plywood  (5) 3 – Rockler 3 Ft. Universal T-Track

 (2) 4x4x8′  (9) Rockler T-Track Intersection Kit
 (3) 2x4x8′  Rockler Pro Lift Router Lift (8-1/4” x 11-3/4”
 (40+) 1 1/4″ wood screws plate)
 (24) 1/4″ x 2″ Lag Bolts  Rockler Router Table Fence
 (20) 2 1/2″ Pocket Hole Screws for soft wood  Rockler 4-Piece Router Table Accessory Kit
 (4) 4″ Polyurethane Casters, Total-Lock Swivel  Safety Power Tool Switch
(Plate Mount)  15′ Heavy Duty Power chord to connect router
 (2) 4″ Polyurethane Casters, Swivel (Plate Mount) and table saw to power
 (1) 4′ – Rockler 4 Ft. Universal T-Track  (8) 1 1/4″ x 1/4″ Wood Screws for the vise
 (2) Rockler Clamp-It® Corner Clamping Jigs
CUT LIST
 78″ x 42″ x 3/4″ – Plywood Base
 (6) 4×4 x 29″ – Legs
 2×4 x 35″ – Short Support Beams
 2×4 x 36 3/4″ – Long Support Beams
 78″ x 29″ x 3/4″ – Middle Plywood Partition
 84″ x 48″ x 3/4″ – Plywood Workbench Top
 40″ x 24 3/4″ x 3/4″ – Table Saw Shelf
 Varies depending on height of your saw- Table Saw Shelf Supports
 12″ x 4″ x 3/4″ Bench Vise Blocks
BUILDING INSTRUCTIONS
PART 1: Build the Table Base

Cut the plywood base to length and width (78″ x 42″). Cut six 4×4 legs to length (29″).
Cut two 2×4 short support beams to length and drill two pocket holes in ends (34″).
Assemble three leg assemblies of 4×4 and 2×4 support beams with 2 1/2″ pocket hole screws and set upside down.
Attach the plywood base to leg assemblies with 1 1/4″ wood screws. Keep the legs square to the outside corners and
center the middle leg assembly to the plywood base.
Attach four locking casters on the four corners through plywood base into 4×4 legs. Predrill the holes to avoid splitting.
Attach two swivel casters in the middle. Use four lag bolts per caster, and add a lock washer and a washer to each lag bolt.
Flip table over and attach long beam supports between leg assemblies with pocket screws. I was able to clamp a block of
wood under the long support to hold it flush with the top of the leg assemblies.
Cut out and install middle plywood partition (78″ x 29″). Cut out the top corners where the end beams and middle beams are
with jig saw. I cut them 1/8″ bigger than the 2×4 so I had enough room to get the partition in easier.
Install middle plywood partition to the long support beams on the table saw side with 1 1/4″ wood screws. You will also be
able to screw into the top support beam as well.
Cut out plywood workbench top pieces and attach with screws (84″ x 48″).
Attach the first layer of plywood workbench top to the top of the legs and beams and screw in place with 1 1/4″ wood
screws. Be sure the center it with a 3″ overhang on all sides.
Attach the second plywood workbench top the the top of the first plywood workbench top with wood screws from
underneath. (Be sure the keep screws out of the path of the router channels for the T-Track.) At this point the table is all
built and ready to use, or continue to add the table saw and other goodies.
PART 2: Table Saw Hole and Shelf Preparation, Miter Lift Preparation
Cut out table saw hole with circular saw and jig saw. Measure out the size of your table saw top and cut it to fit that size.
Use tape to protect the edge of the plywood.
Cut out and build table saw shelf
Cut table saw shelf to length and width (40″ x 24 3/4″). Cut out corners to wrap around the legs. Add 1/8″ to the leg
thickness of 3 1/2″, to give room to install it without being too tight. Cut out table saw shelf supports.
Assemble shelf and supports with screws. I used these awesome corner clamping jigs for holding the supports in place
while I screwed them together with 1 1/4″ wood screws.
Cut out hole for table saw dust to fall into. This hole is 3/4″ smaller than the base of the table saw. That way the table saw
still has something to sit on.
Attach shelf to table with 1 1/4″ wood screws. I jacked up the shelf and clamped it in place so I could screw it in
underneath. I also squared it off and screwed it in through the partition.
Rout out miter gauge outfeed channel in workbench top. Rout it long enough to get the miter past the blade of the table
saw.
PART 3: T-Track Preparation and Installation

Route out T-Track channels over the entire table at 3/8″ deep. You want the channels to be deep enough to keep the top
of the T-Track flush or just below the surface of the table top. See top view of table for layout of channels. This is where the
T-Track intersections will go.
Router Lift Preparation: Cut out router lift hole with router at the depth of the lift plate, just slightly bigger than 3/8″ deep.
Start routing in the middle and work your way around in circles until you get to the edges. At the edges I clamped down
wood as bumpers to keep my lines nice and square.
Sand and polyurethane table top. I sanded with 120 grit sand paper. I also rounded all the corners by hand so they
wouldn’t be so sharp. On the outside edges I used an orbital sander to remove all the print on the boards and level the two
top layers together. After I sanded I brushed in four layers of scratch resistant polyurethane. I also sanded with 150 grit
sand paper between coats. I wanted it to be a really nice smooth surface.
Now it’s time to install the T-Track. I started with the intersections then cut the T-Track to length with a metal blade on
the jig saw. See the blog post for more photos of the installation.
Finish up the table by installing the table saw, router lift, and bench vise. Photo instructions are included in the blog post at
www.remodelaholic.com/table-saw-workbench-building-plans-rockler-t-track-system
Send us a picture @Remodelaholic #imaremodelaholic on Facebook and Instagram

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DIY TABLE SAW WORKBENCH

WITH ROCKLER T-TRACK SYSTEM

Find the original photo tutorial and additional info at

 (4) Sheets of Plywood  (5) 3 – Rockler 3 Ft. Universal T-Track

PART 1: Build the Table Base

Cut out and build table saw shelf

PART 3: T-Track Preparation and Installation

Send us a picture @Remodelaholic #imaremodelaholic on Facebook and Instagram

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