January 27. 2008
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Saw & Router Station

The central powertool in my woodshop is my Ryobi BT3000 Precision Woodcutting System (tablesaw). This saw came from the factory with a retangular metal stand. After a few years i outgrew its' use. Sam Conder, owner and Adminstrator of BT3Central borrowed from several other designs including the U.T.C. (universal tool cart, citation escapes me) and designed, planned, and built his own BT3 moble saw cart, aptly named Maroon & Maple. My saw/ router cart follows his plans with a few modifications of my own. Namely an enclosed router box and horizontal sliding saw tray.

Even after several years mine is still a work-in-progress. I add to it as I find time when the shop is not occupied by other projects. My aim once finished is to have a functional eye pleasing workstation as my workshops center piece. The entire fron will be covered in Black walnut with a bit of birdseye maple mixed in with an oil finish. As you can see from the images at this wrighting I am close to seventy five percent done. I also plan to add an attached outfeed table the full width featuring moveable/ removeable spacers to allow the SMT (sliding miter table) full function on each side of the blade plus a depth of three feet and the addition of at least one woodworking vise along with dog holes. This will do double duty as my work bench.

A few construction details: Most all of the carcase was built with 3/4" MDF. The back is 1/2" MDF. The top that holds the Router station is a double layer of 3/4" MDF with a high pressure laminate applied to the surface. This was edged on all four sides with black walnut. The saw's rails attach dirctly to the front and have thin spacers between the cart and the rear rail. Moving the rails is still possible but requires using a ratchet, socket, universal swivel joint and several extensions to reach the rear bolts. The front ones are only slightly more accessable. The lower most front panel as well as the sides willsomeday be painted with a light pastel purple a few shades lighter than the trim in my shop.I you won a Ryobi or Ryobi manufactured Crtaftsman branded version of the BT3 saw and am planning to build your own cart feel free to use the sites contact button to ask any questions you may have.


click for full view This view shows the front of my saw cart. In the foreground you can see the BT3K Saw. My current dust control system is shown far left, a Shop-vac brand shop vacuum with a 2-1/2" hose.
click for full view As mentioned my saw is mounted on a tray that slides horizontally. This enables me to extend my rip capacity. It slides on two ball bearing full extension drawer slide layed flat in dadoes. The tray also has two hinges that allows the saw body to tip up for matainence. Normal useage the saw tray is in the closed position, this image shows open position.
click for full view The tall drawer on the left is my blade storage, a two sided "A" frame with storage on each side. This is mostly identical to Sam's design. The door center right with the birdseye maple raised panel is my router box. Currently I plug the router's power cord into the BT3K's switched power outlet when in use. I may sometime in the future wire in a different switch. In my current use I am able to only use one power cord to power both the saw and router plus the BT3K switch has a hinged cover that turns off with just a press of the cover. It also requires a deliberate effort to raise the cover and switch the tool on which in my humble opinion is a great safety feature. All of the open spaces will someday get drawers installed.
click for full view My router station consists of a Marvel 60 plunge router with the plunge springs removed mounted to a Rockler's aluminum router plate (size large). The "T-track" on the left of the plate is for attaching hold-in feather boards along with serving as a guide for some jigs. My sliding dovetail jig is one such jig. The two "T-tracks" front and back on the right secure my Router Fence as well as a few other jigs. I am also able to use "T-bolts" to secure my portable Ryobi 10" planer to the workstation for any planing I need to do.
click for full view My Router Fence is detailed elsewhere on my site.
click for full view This final picture shows up close some of the highly figured black walnut that I've used to face the front of my sawcart. This one happens to be of the blade storage drawer. The pulls are also shop made; 1/2" roundover on top, 1/2" cove under the bottom , and beveled on each end. I used more birdseye maple for these.