Large Cutting Surface for Track Saw (TS 75 EQ)?

[EcoMouse]

Hi all, my first Festool and I couldn't be happier! I've wanted a table saw solution, but wanted to keep my shop open for larger projects or metal work. (I do all kinds of stuff in the shop, and need to switch up tasks between days. Some days it's foam or composites, most days it's metal, and of course wood needs to be handled)

So the track saw was on my must have list. However, I've only seen a handful of ideas on how to tackle a 4x8 sheet. I've seen a couple of fold up against the wall, open deck ideas. That didn't really work for us, our wall space is already spoken for. But I liked the concept. However, I didn't like the idea that you just cut into the cross braces over and over again.

Then I ran into the centipede table! http://centipedetool.com (If you buy it from Lowes.com, you can enter a common 10% off coupon and it get delivered for less than $100!)

That's perfect... because a lot of what we do, sometimes has to be done on site. Which is why the TS 75 was a perfect addition.

BUT... this brings me to my question. What can I use as a sacrificial board underneath? I could have sworn I saw a pic somewhere that showed a track saw user using the pink foam boards. They are great, and dense. But unfortunately they are not to be found in the big box stores anymore, Dow (blue) or Corning (pink) in the 4x8 sheets. Is there a way to still get them in one sheet, delivered?

Are there any other ideas other than MFD sheet. (We try not to use that crap in our shop)

 

[dltflt]

I am using white foam from the big box store and it works just fine.

 

[rvieceli]

My Lowes carries the blue Dow extruded foam in 1 inch and 2 inch thick 4x8 sheets. the Home Depot nearby has the pink Owens Corning stuff in the same sizes. Might want to check around

 

[duburban]

blade wear in foam? I know this process works… but rip some foam on the table saw and you'll see how detrimental to the blade this chemical junk is.

 

[Cheese]

But unfortunately they are not to be found in the big box stores anymore, Dow (blue) or Corning (pink) in the 4x8 sheets. Is there a way to still get them in one sheet, delivered?

First [welcome] to the FOG.

Owens Corning 4x8 sheets can be purchased at Menards.

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Forgot to add, I think this is 1 1/2" thick foam.

 

[EcoMouse]

I used to make foam R/C airplanes when I lived in California. The pink and blue stuff was readily available. Then around 2005 or so, I started to notice that it was getting harder and harder to find. Eventually, you'd drive all over town to pick up the last sheets the stores had.

I was recently back east and noticed that a local Home Depot had tons of the pink stuff in stock.

I currently live in Nevada, which is basically East California. So, no blue or pink foam in 4x8 sheets. They do have the dingy pink foam at Home Depot in 2x2 project sheets. But nothing like it was. But that crappy styrofoam with the single sided mylar face can be found all over. It just makes quite a bit of mess when cutting into it.

I was hoping that you guys would have some other solutions as a sacrificial cutting surface for the TS 75.

(What's a Menard's? Is that like Home Depot in Canada?)

 

[tjbnwi]

Knock table and foam.

Tom

 

[Wooden Skye]

I use 2 sheets of 2x8 ridgid foam.  They are 2" thick.  They have a tongue and groove in them so I just slide them together.  I would prefer a single sheet, but storage of the 2 sheets is easier in my situation.

 

[peter halle]

One of our members offered me a tip long ago about connecting narrower sheets together with duct tape to create a less wieldy package.

 

[JimD]

I made a lattice of 1x4s many years ago.  It's about 3'x7'.  I used to put it on top of my table saw and workbench.  I cut down my table saw after getting the track saw and got rid of my old workbench when we moved.  So now I use the same lattice on a couple sawhorses.  I've used 7/16 waferboard as an underboard too.  It worked. But I think the lattice is a better solution.  After 10 years or so of use, the top surface has some cuts in it.  But it still works fine.  The other side hasn't been used yet.  So I think it will outlast me.  But soon I hope to find the time to make up a Ron Paulk style top for a workbench and that will become my main cutting surface.  He uses pieces of scrap plywood under the surface being cut to avoid cutting into the workbench top.  I plan to do the same - unless I happen to have some pink foam around. 

An advantage of the Paulk style top is the ability to put tools under the top where they aren't on the work surface but are still handy.  I think that will be a very useful thing.

 

[curt boyer]

This is what I made and use. It's MDO ply that I ripped to 4-1/2" wide and notched so that I have a 4'x 8' support surface. When broken down it  is easy to store. Foam is good if you have a shop but not very easy to store when your mobile. Besides a cutting table I throw a sheet of ply on it and I have a flat and sturdy assembly table.
Cheers
Curt

 

[tjbnwi]

My table without the foam on it.

Tom

 

[Cheese]

(What's a Menard's? Is that like Home Depot in Canada?)

Menard's home improvement chain. They're are over 280 stores in 14 states. John Menard sponsors NASCAR stock car racing, while his son Paul is a driver for Richard Childress Racing.

 

[Cheese]

My table without the foam on it.

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[Wooden Skye]

My table without the foam on it.

Tom

Tom

On your table, between the first and second cross piece you have an additional cross piece that isn't flush with the other.  It appears that there is another similar piece at the end.  What are those sections for?

 

[rvieceli]

I'm not Tom but those are the legs. There are some more pics here:

http://festoolownersgroup.com/festool-tool-problems/parallel-guides-not-cutting-parallel/msg353010/#msg353010

I believe the slots for the legs are angled in at the top a little but as well.

 

[tjbnwi]

Yes, those are the legs.

Tom

 

[EcoMouse]

I have foldable metal saw horses. I like the idea of just adding some extrusions between them. Simple.

But basically, most people like foam tops?

 

[Cheese]

What's not to like about foam tops?
Cheap
Kind to the saw blade
Light weight
Easily transportable
Available at every big box including Menards
It's kind of a no-brainer.

You just have to make sure you have an underlying structure below the foam that fully supports the foam panels and ensures a flat cutting surface for the track rail.

 

[rustym]

Check out this thread "Has anyone built Gary Katz's assembly and cutting table".  Lots & lots of great ideas.

Rusty