When I first moved into my workshop in Braddock, PA more than a year ago, I made a plan to deck the place out top to bottom. I completed a number of projects that have really turned my workspace into a fun and functional space, but Sam and I are always coming up with ideas for updates and improvements.
One day while discussing nuclear fission and quantum phenomena over a fine cup of Black Rifle Coffee, Sam and I thought of our next big shop build: the ultimate miter saw station with a built-in downdraft table. Able to hold my miter saw, hand tools, maybe even storage bins, and suck out all the dust with ease, our vision for the project, drew up some miter saw station plans, and got to work.
As you’ll see in this video, Sam and I had a blast creating this ultimate miter saw station (with a few minor hiccups along the way). So check out the video below, my project overview, and purchase the plans to build one for yourself!
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Kick-off this project by building a solid carcass for the structure. I like to start by cutting then taping up base panels to notch them in the correct spots. I create a ¾ -inch relief and just the pieces with a jigsaw. I then tack the pieces together with brad nails, reinforcing with screws once I see that everything fits nicely. Make sure you spread the brad nails far enough apart to save room for the screws. Add your edge banding now if you want -- or if you’re like me, you can decide to try it again at the end of your project. Your call.
Once your carcass on your miter saw station is built, it’s time to get to the important part: the miter saw itself. The miter saw station plans include a central platform for the saw that helps you feed your wood level to the rest of the station. Create this by cutting down your wood on the table saw and shaping out your grooves with a router. Fasten this platform to the carcass with tite bond and brad nails, allowing that to dry while clamped. Secure it with screws, sand the surface, and route the edges
As I’ve learned from previous projects, it’s much easier to add drawer slides before moving forward. So take the time to add your drawer slides.
If you’re adding the downdraft table feature to your miter saw station (which you totally should), cut out the dust collector from the carcass.
Once your dust collector is cut and your drawer slides are in, screw on the tops to you miter saw station. From there, it’s time to start building upwards. That’s right, cubby time. Start building your cubbies by cutting out the wood shapes on either your miter saw or table saw. Assemble these with glue and brad nails, screwing them together once the glue has dried. Route and sand the edges to make them smooth.
Take the time here to also create the sliding doors for the cabinet. These cubbies will need insets for sliding. Cut out those insets then drill the drawer pulls for the cabinet doors using a Forstner bit. Assemble onto the carcass.
Next, it’s time to add innovation (read: a floppy piece of plywood) to your miter saw station. Secure a bendable piece of plywood to the top portion of the saw platform. This is there to collect sawdust and move it toward your dust collector, making cleanup a breeze. Washers will make this a little easier and more secure. Then, use an Exacto knife to cut away the top excess plywood.
Once everything else is built up, it’s time to make the hardwood pieces. This involves joining some pieces, lots of sanding, cutting out some door handles and channeling out some grooves.
I recommend beginning with a template for your drawer pulls. Cut this out on a band saw on each drawer, using a spindle sander to carve out the hollow. A templating bit will do the trick, too.
Next, create your sliding doors for the cubby recesses. You can make these fit by sizing them down with an edge sander. Then build up your drawers with the same glue/nails/screws pattern as before, adding the slides to the sides once dry.
Once your drawers are built and in place, be sure to add a finish to your miter saw station. This will protect it from inevitable bumps and chips from working in a shop.
Sounds easy enough, right? Punch this project in the face as soon as possible by downloading the plans for yourself and getting started! The plans give you precise measurements and detailed steps, making this project your new pride and joy without all the hassle.
Like this project? Be sure to check out some of my other latest home & shop projects:
Want to try this build out for yourself? Download the digital plan now for step-by-step instructions, measurements, and a detailed look at how to punch this project in the face.