At a glance
Finished dimensions
Overall sizes
- Base
- 72 × 16 in, or the saw's foot depth plus 2 in if deeper
- Saw zone
- S + 1 in wide (S = width across the saw's feet)
- Wings
- Each (71 − S) ÷ 2 in long, top H above the base (H = saw table height above its feet)
Materials
| Item | Quantity | Note |
|---|---|---|
| Plywood sold as 3/4 in | Half a 4 × 8 ft sheet | At least 1/2 in thick for the base, as DEWALT specifies; measure t |
| Screws for the saw's foot holes | 4 | Short enough that the tips stay inside the base |
| 1-1/4 in screws and glue | As needed | Wings and fence strips |
| Clamps | 2 or more | Base to bench |
Cut list
| Part | Qty | Dimensions | Material |
|---|---|---|---|
| Base | 1 | t × 16 × 72 in | Plywood |
| Wing top | 2 | t × 16 × (71 − S) ÷ 2 in | Plywood |
| Wing rib | 6 | t × 16 × (H − t) in | Plywood |
| Fence strip | 2 | t × 3 × (71 − S) ÷ 2 in | Plywood, one edge straight |
Tools
- Circular saw with a straightedge, or table saw
- Drill/driver
- Square and straightedge
- Clamps
What the saw's manual allows
- Mount it firmly. DEWALT's DWS779 manual has holes in all four feet and says to mount the saw firmly to a stable surface; to keep it portable, it can be mounted to a piece of plywood 1/2 in thick or more that is then clamped to a work support.
- Keep the bottom flat. The mounting screws must not protrude from the bottom of the plywood, which must sit flush on the support.
- Clamp the base, not the saw. If a saw is clamped directly, DEWALT says to clamp only on its clamping bosses; on this station the clamps hold the plywood.
- Support long work. DEWALT says to always support long pieces with extensions, sawhorses or similar, and never to use another person as a support. The wings are that support.
Other saws have their own manuals and mounting holes; follow yours where it differs.
Measure your saw
| Letter | Measure | Used for |
|---|---|---|
| S | The width across the outside of the saw's feet | The saw zone, S + 1 in, and so each wing's length, (71 − S) ÷ 2 |
| H | The height of the saw's table above the bottom of its feet | The wing top's height; each rib is H − t |
| t | Your plywood's actual thickness | The rib height and every part's thickness |
Measure with the saw on a flat surface. For a sliding saw, also check the space it needs behind it.
For example, a saw 22 in across its feet with its table 4 in above them needs a 23 in zone and two wings 24-1/2 in long, with ribs 4 − t high. These figures are an illustration, not any model's.
Building it
Base, saw, wings and fences
Cut the base
Cut the base 72 × 16 in; if your saw's feet are deeper than 14 in, make it the foot depth plus 2 in.
Mount the saw
With the saw unplugged, centre it on the base, mark its foot holes, and screw it down with screws short enough that their tips stay inside the plywood.
Build the wings
Cut three ribs per wing to H − t and the wing tops to length. Glue and screw a rib under each end of each top and one in the middle.
Set the wings
Stand each wing on the base beside the saw, leaving 1/2 in clearance, and check with a straightedge laid across the saw's table that the wing top is level with it. Plane or shim the ribs if needed, then screw the ribs to the base from below with screws that do not protrude.
Fit the fence strips
Hold a straightedge against the saw's fence and screw each fence strip to its wing so the strip's straight edge lines up with it.
Clamp it down
Set the station on a level, firm bench and clamp the base at both ends. Make a simulated cut with no work on the table to check that nothing interferes.
A bench to put it on is in workbench plans; the saw's types, capacities and setup are in the miter saw guide, and builds to make with it in miter saw projects. Table saw benches and outfeed tables are covered separately in table saw workbenches. This station belongs to the shop projects family.
Safety— The saw's manual governs
Unplug the saw before mounting or adjusting it, support every long board, and never use a helper as a support. Shop practice is in woodworking safety rules and protective equipment in woodworking safety equipment.
Before the first cut
- S, H and t measured on your saw and plywood
- Saw screwed through its foot holes; no screw tips below the base
- Wing tops level with the saw table
- Fence strips in line with the saw's fence
- Base clamped to a level, firm bench at both ends
- Simulated cut made with no work on the table
Sources
A BenchRoot design. The mounting follows DEWALT's manual for its DWS779; check your own saw's manual, which governs. Sizes that depend on the saw are letters to be measured, not values for any model; the drawing uses S = 22 and H = 4 only as an example. It was drawn and checked but not built or tested for this page.
- 1.
Used for: Mounting holes in all four feet; mounting the saw firmly to a stable surface, or to a piece of 1/2 in or thicker plywood clamped to a work support; mounting screws that do not protrude from the bottom of the wood, which must sit flush on the support; clamping the saw itself only on the clamping bosses; always supporting long pieces with table extensions, sawhorses or similar, never with another person; a level, firm work surface; a simulated cut with no workpiece after each angle change.
- 2.
Panel Thickness Tolerances and Labeling (Technical Topic TT-054). APA — The Engineered Wood Association, 2013.
Used for: Panels labelled by actual thickness rather than nominal alone, so plywood sold as 3/4 in may be thinner.
- 3.
Hand and Power Tools (OSHA 3080). Occupational Safety and Health Administration, 2002.
Used for: Disconnecting tools before changing accessories, and following the maker's instructions.
About this project
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