Chop Saw End Stop

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When I joined the staff here at aw, I left behind one of the most beautiful workshops east of the Mississippi. 'ITicrc was plenty of space, lots of light, and a view of 188 acres of rolling pasture.

Now I'm in the fast lane, hard at work editing, and trying to fit my machines into a new, much smaller shop . .. the basement. Some of my bigger machines are never going to fit there, so I've been adapting the smaller tools to give them a bigger capacity like my Hitachi sliding compound miter saw. This saw was already getting daily use, and I knew that with a work station around it, it could do most of what my big radial arm saw used to do. (For a review of sliding compound miter Z saws, see page 40.) |

How it Works

The principle of this station is simple. Extension tables support stock on either side of the saw while wooden fences keep long workpieces square to the blade. (Sec Fig. 1.) Each fence has a stop block and a self-adhesive tape measure attached, letting me make single or repetitive cuts without ever reaching for my hip-side tape. Also, I can flip the stops up and out of the way when I need to square up the end of a long board.

Designing to Fit

To design the station, I got together with Fred Matlack and Phil Gehret, aw's Design Shop veterans, and we figured out what we wanted it to do. First, it had to have support tables long enough to handle large slock on either side of the blade. Second, since I cut a lot of molding and narrow stock to exact lengths (usually 36 in. or less), the station s stop blocks had to index to these dimensions. Third, it had to be portable so I could take it with me for occasional jobsite work. And finally, since it was going to take up valuable space in my small shop, it had to serve a dual purpose as chop saw station and storage unit. In a

Chop Saw Station Plans

Building a Workstation Around Your Miter Saw Will Make This Tool More Versatile pinch I can even use the top of the base cabinet as an assembly table.

The design we developed will fit my Hitachi sliding compound chop saw. If you want to adapt this design for any other brand, you may have to modify the cabinet top and support tables. (Sec Fig. 2.)

Building the Station

We began building from the ground up, making the cabinet first, then the bottom frame assembly, and finally the outfecd tables, fcnccs and stop blocks. (See Fig. 1.) Most of the construction is pretty simple, but there are some steps and techniques I'll explain that help the job go smoothly.

The cabinet, which is glued and screwed together, is made from plywood with a poplar u face frame and

® a plastic lami nate top. You can tailor its size to fit your needs, or forgo the cabinet and simply bolt the station onto 2x4 braces nailed to the shop wall.

To secure the station to the cabinet, I attached sash catches at each side of the cabinet. These keep the station from lifting if you put a heavy weight, like a large timber, at one end.

The outfecd tables are attached above and the bottom frame below a !4-in. plywood panel, creating a rigid assembly without adding undue weight. The entire station fits over two removable locating blocks (see Fig. 1), which keep it from sliding on the cabinet top.

We used lumbervard 2x4s to frame

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