Author Topic: Designed a small and affordable miter saw station  (Read 1779 times)

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Offline ryanjg117

  • Posts: 131
Designed a small and affordable miter saw station
« on: January 16, 2019, 01:47 AM »


















Fooled you.

I've been kicking around the idea of using aluminum extrusion for SysPorts and finally found a (relatively) affordable vendor: Misumi. This design uses their 30x30mm extrusions, which are significantly more affordable than the next size up (40x40) yet plenty strong for this application. I'm expecting the extrusions to cost in the ballpark of $500 for this project, which really isn't bad and significantly less expensive than 80/20 Inc. Of course, it's the fittings that kill you, but I'm using either the most affordable brackets Misumi offers or re-using some existing hardware (t-nuts, screws, etc) to try to keep the costs down.

I've sized this to perfectly house the Kapex in the middle, with the plywood overhang mating right up against the edges of the Kapex work surface. Height of the miter saw mount can be adjusted easily, and also replaced in the future for a different saw. I toyed with some dust collection shrouds or a downdraft table, which I can always add later, but decided to keep it simple [eek] for now.

This is a really long assembly (almost 15 feet long), designed to take up my entire back wall of the shop. Yet I still wanted occasional mobility, so I added some ball transfer switches (which I just recently discovered, super cool as they are extremely low profile but many are able to take a lot of weight) and leveling pads that screw into the bottom of each extrusion.

Of course, the appeal of aluminum extrusions is total flexibility in mounting the 31x SYS-AZ drawers. I'm planning on mounting the bottom drawers first, then using a plywood sheet as a spacer to ensure a consistent gap between each cabinet. Spacing at the top will be variable, which is fine as I'll need to provide some space underneath the perforated top for clamps to pass through without interfering with the systainers. The spacing between each extrusion will be a perfect 427mm, driven by the CNC holes on the top and bottom plywood panels.

One problem I've always had with my homemade SysPorts is balance. My first SysPort is always threatening to tip forward if I just look at it wrong. A follow-up design I made had some hidden storage shelves on the back, just to counterbalance it. In this case, I also ended up with substantial space behind the drawers due to the overall depth of the work surface. I wanted a 22" deep countertop to allow for storage of, sadly, additional systainers along the back if necessary. I've tried to put that back space to use with some rail storage and shelves for longer items like straight edges.

I'm aiming to cut the plywood and acrylic for the flag stop with a Shaper Origin.

I'm not going to tackle this project for another month or so, but interested in getting any input or design improvements now. Happy to share the 3D or DXFs files and material list if there is interest.
« Last Edit: January 16, 2019, 11:00 PM by ryanjg117 »

Offline Gregor

  • Posts: 1204
Re: Designed a small and affordable miter saw station
« Reply #1 on: January 16, 2019, 04:21 AM »
Fooled you.
Till some moments ago I liked you...

BTW: all images are broken, please use an image host that works or (preferably) upload them to the forum.

Offline Mario Turcot

  • Posts: 760
Re: Designed a small and affordable miter saw station
« Reply #2 on: January 16, 2019, 08:26 AM »
BTW: all images are broken, please use an image host that works or (preferably) upload them to the forum.

I second that... I want pictures  [wink]
Mario

Offline ryanjg117

  • Posts: 131
Re: Designed a small and affordable miter saw station
« Reply #3 on: January 16, 2019, 11:01 PM »
Sorry guys, fixed the images now (I think).

Online duburban

  • Posts: 1009
Re: Designed a small and affordable miter saw station
« Reply #4 on: January 17, 2019, 01:22 AM »
Rhino3d?
helper: i used a festool "circular saw" to do something simple and it made it really hard

me: exactly, it makes simple cuts complicated and complicated cuts simple

Offline neilc

  • Posts: 2594
Re: Designed a small and affordable miter saw station
« Reply #5 on: January 17, 2019, 09:51 AM »
You're showing off, Ryan!  That looks great.

Why not go full width with the fence t-tracks? 

One downside of your approach is the sawdust from every project filters down into the systainers below given the holes.  You might consider some masonite dust panels above the stacks.  1/4" would still allow clamp use but give you an easy way to clean up. 

Alternatively, go to t-track across parts of the top rather than the holes. 

Offline Mario Turcot

  • Posts: 760
Re: Designed a small and affordable miter saw station
« Reply #6 on: January 17, 2019, 10:05 AM »
Very nice design  [thumbs up]

One suggestion i can bring is about the fence. Do you have the fence mainly for repeatability? If so I suggest to do what Make something did on his mite saw station.



A fence is often useful but it can fool you [tongue]
« Last Edit: January 17, 2019, 10:08 AM by Mario Turcot »
Mario

Offline Trevin

  • Posts: 84
Re: Designed a small and affordable miter saw station
« Reply #7 on: January 17, 2019, 12:20 PM »
Hi All,

I did something similar with 80/20.  I got the 80/20 for free so I could justify it.  I added a top section for even more storage.  What do you think?

Trevin
Festool: MFT3 (x2), OF1010, OF1400, LR32, Domino DF500, Domino XL DF700, Kapex KS120, TS-75, Carvex 420, CXS, C-18, Vecturo OS 400, DTS 400, Pro 5, Rotex 125, VAC-PMP, VAC-SYS-1, VAC-SYS-2, CT-26 (x2), CT-SYS, SYS Light DUO, SYS-ROCK
Other: Minmax FS41, Sawstop PCS (3HP, 52"), Laguna BX14, Jet 17" Drill Press, Rikon 70-220VSR Lathe, Incra LS Router Station, Laguna P/Flux 3 Dust Collector

Offline Mario Turcot

  • Posts: 760
Re: Designed a small and affordable miter saw station
« Reply #8 on: January 17, 2019, 12:23 PM »
 [jawdrop] The top is all made of extrusion? [jawdrop]

No doubt it's sturdy  [big grin] and a lot of storage  [thumbs up]

Love the T-Lock drawer pulls  [smile]
Mario

Offline Tinker

  • Posts: 3682
Re: Designed a small and affordable miter saw station
« Reply #9 on: January 17, 2019, 01:21 PM »
>>>This is a really long assembly (almost 15 feet long), designed to take up my entire back wall of the shop.<<<

That is a clever way to store your rails. If the setup takes up the entire wall, how will you have access to those rails.

When i first set up my shop nearly 50 years ago, I was limiting myself to just one little 8x8 corner of the cellar. I had only a RAS but occasionally, I needed more space so I just cut a hole in the wall for the overhang for cutting longer boards. I cut the hole in the wall so the bottom lined up prefectly with the table of my RAS. I ran into problem only with ripping. The other side of my little space was the furnace. It was inconvenient to chop a hole in the side of that. For ripping anything longer than 4 feet, I just toted the board up thru the house and cut it on saw horses. After a few trips thru the house, tracking sawdust across the floors, I finally persuaded my Dearly Beloved that it was too cold in the cellar to go along with her dream of a playroom. I removed the wall and eventually, -------- well ----------I developed the philosophy that "he who dies with the most tools wins."

Tinker
Wayne H. Tinker

Offline Mortiser

  • Posts: 35
Re: Designed a small and affordable miter saw station
« Reply #10 on: January 17, 2019, 02:53 PM »
@ryanjg117 , that's an impressive project. Will be very interested in seeing pictures as your build progresses. I think you state your top is 22" deep. Can you share the depth of your extrusion framework? Would love to see a cut list of both aluminum and mdf(?) if you have one.
Thanks.
Rich

Offline online421

  • Posts: 110
Re: Designed a small and affordable miter saw station
« Reply #11 on: January 17, 2019, 03:37 PM »
mitre station... last time I had a mitre station was 2012...
Griggio Unica400
Felder AD951
Masterwood OMB1V
SCM 5 RCS1100
Casadei FV110
Chicago Pneumatics CPRS10500
Ceccato CDX 12
Holytek DC006
Festool DF700XL, CT36, LEX3
JLT 190BM2, JLT 79K10
Danfoss VLT 2880
Sicar TOP6

Offline Gregor

  • Posts: 1204
Re: Designed a small and affordable miter saw station
« Reply #12 on: January 17, 2019, 04:11 PM »
One suggestion i can bring is about the fence. Do you have the fence mainly for repeatability? If so I suggest to do what Make something did on his mite saw station.
Fenceless fence is a nice idea, but I would set the T-track back so I can have multiple flipstops.

I also thought about using extrusions, but find the pricing a bit prohibitive compared to using wood, screws and glue. But should I ever decide to build something from extrusions I would likely go for the Item Automatic Fastening Sets as they're mounted out of the way, moveable, can be installed without the need for profile machining (no extra drilling and such, just screw into the end of the slots of the profile) and are only [blink] around 6€ per 90° connection (one which goes into both opposing sides of the profile).

You might know these, a small version of them is used in the Festool MFS.
« Last Edit: January 17, 2019, 04:17 PM by Gregor »

Offline jeffm13

  • Posts: 15
Re: Designed a small and affordable miter saw station
« Reply #13 on: January 27, 2019, 12:32 AM »
Looks great and I love the flip stop!  I'm used the 30mm Misumi extrusions, although not to the same extent. Any chance you could happen to have part #'s for the parts used for the flip stop?
Festool: TS75, DF500, DF700, OF1400, LR32, ETS EC 150/5, DTS400, RS2E, T18, TXS, CT36, PS420, FS1400 (2), FS1400/2-LR 32, FS 2424/2-LR 32, Tradesman/Installer Cleaning Set; TSO: MTR-18, GRS-16 PE; UJK: Parf Dogs, Super Dogs, Parf Guide System MkII, Seneca: Parallel Guides, Domiplate, Domishim; Makita: 3000mm Guide Rail; Jessem: Mast-R-Lift w/metric conversion kit, Pow-R-Tec Router, Mast-R-Fence, Mit-R-Slide, ClearCut Stock Guides; Grizzly: G0441 Cyclone, G0691 Table Saw; Laguna: 18BX Bandsaw; Robland: X31 Combination Machine; Incra: MagnaLock Cleansweep; Woodpecker: 1281-300mm, 600mm T-Square, 1200mm Ruler, 1200mm Story Stick Pro; Bosch: GCM12SD Glide Miter Saw