New Paulk Work Bench with router table

[crpaulk]

Disclaimer: I sell plans for my bench online.

I just finished a remake of my Paulk Work Bench adding a router table. I had a great time designing and building it. I video tapped the making of the bench and plan on uploading a series showing how it is built as I edit them. Festool is the major driving force in my wood working the past few years and it shows in the video. I am amazed at the number of comments and emails I get from carpenters telling me they had never heard of Festool, but now have a Kapex or TS 55. Most think I am paid by Festool, but I let them know otherwise.

Ron

 

[Wooden Skye]

Ron,

Great addition with the router table.  I can't wait to see the build videos.

 

[Kevin Stricker]

Ron,
  Have you had any feedback on using your table design on the DW745 table saw?

Tanks,

Kevin

 

[Rocky]

Just ordered mine.

 

[crpaulk]

Kevin,
I am not sure what you are asking here? If you are asking about the DW, then not much feed back on the saw. If you are asking about the bench, I have had enough feedback to fill the library of congress, but none specifically to the DW. I use the DW and find it to be the best option for what I do. I had the Bosch and Makita as well, but sold them and kept the DW. This is my experience, but the guy who bought one of my Bosch saws swears by it and prefers it to the DW. Any portable you like will be improved with a solid support base and large out feed.

Hope this helps,
Ron

Ron,
  Have you had any feedback on using your table design on the DW745 table saw?

Tanks,

Kevin

 

[Kevin Stricker]

Sorry for the confusion.  Specifically I was wondering if you had set up or knew someone who had modified your design for the DW745.  The fence prevents using pipe to mount the saw as it's rack and pinion mechanism is lower than the table, which seems to be different than the DW744.

Thanks,

Kevin

 

[J.Patching]

I just received the plans from Mr. Paulk today. I also wonder about mounting for the 745 as its the saw I'll be using. I'm going to investigate what it takes, but don't imagine it's going to be too hard. The plans, by the way, are very well put together with many details and specs. Can't wait to start cutting plywood!

 

[J.Patching]

I think I've come up with a somewhat easy solution for mounting a DW745 to the bench. From a quick look at the saw, the table has sections that are thicker (bosses?) at the front and back on the right and left sides. It seems like one could drill and tap some 1/4-20's or 5/16 holes and attach some 1-1/2 x 1-1/2 angle iron to the sides of the table. Then one could makeup and attach the ply mounting peices. These would allow the saw to use the same retractable conduit that Mr. Paulk has spec'ed out, though the mounting location and support peices will probably have to relocate.
  I'm going to investigate it closer this weekend and will post what I come up with.

 

[J.Patching]

Here are some pics of the DW745 mounts. I used 1-1/2"x2"x 1/8" angle iron. First, I filed the "bosses" relatively flat, removing the coating and some aluminum. I cut the angle so it was ~5/32 back from the front and back of the table and 1/8" down from the top. The measurement isn't critical as long as there is room for the fence to move by. I used 1/4-20 machine screws counter sunk in the angle. When drilling and tapping the table, I had no interference on the right (fence lock) side, but the left side is a slightly different story. Since the housing is so tight to the inside of the table it's hard to anticipate what you might hit whilst drilling. I ended up running through a cast rib, and the side of the a screw placement. It's not that big of deal, as I just ground the end of a 1/4-20 tap to make it so I could tap all the way to the bottom of the hole, then cut my screws accordingly. I used 2 screws per boss, so 4 per side and 8 total. I'll post tomorrow when I get to mounting it to the bench.

 

[Kevin Stricker]

Nice job!

 

[crpaulk]

I don't have any experience mounting any table saw other than the Dewalt 744. Many others have come up with solutions for other brands and models. If Festool would bring their TS to the US, I would be the first to order.

 

[crpaulk]

Ron,

Great addition with the router table.  I can't wait to see the build videos.

The edit process is high on my priority list now that I am back home and finished with the chores. I recorded the build process from start to finish talking sometimes and others just letting the video run, so I may have to do a lot of voice overlay. Additionally, the results are in question. When I shoot a video for Youtube, it is usually shot multiple time and then the best parts are cut together. This time I only have one run through. I would like to have someone shooting the videos so they could move around, zoom in and out, monitor the audio and generally keep tabs on the whole process, but one video can take days so it would be costly to have a cameraman the whole time. Regardless, I will put them up upon completion. Also, I hope the latest video catches on as it answers a lot of questions the first video raised. Currently, the first video still gets 300 new views a day while the second is only 100 views per day, so I am left to answer individual questions via email everyday. With almost 400,000 views the first video generates at least 20 emails a day with questions, the main one being, "Do you have plans for your bench." It is a part time job just keeping up with that first video. Who would have know 100s of thousands of carpenters from around the world would find the Paulk Work Bench just right for their needs. A bit of history: when I put the first video up, I had no plans for the bench, nor had even considered providing any. My though was to show the bench via video for fun and just to share my ideas with other carpenters. I guess the old adage "Build a better mouse trap" is true. The work bench has taken on a life of its own and I have to hang on and go with it. I have been contacted by a large tool manufacture about mass producing my bench. At this time I have put them off as I like providing the plans to individuals and continuing to refine it. Selling it would be more profitable and a lots less work, but I really enjoy the interaction with carpenters around the world. The last time I checked, I had some form of communication with carpenters in 194 countries. Google is very helpful in translating to allow us to email back and forth.

Ron