Folding and rolling mitre saw station

[RainbowDiY]

Pine timber used to build a collapsible mitre saw station built on rollers.

• The project
• Tools and materials
• Steps
• More inspiration for your project

The project

I have a tiny shed - 2m x 900mm. It’s basically to store my tools and I bring them out into the backyard to make things. I wanted a way to create rolling tool chests that also housed my big tools like my mitre saw and table saw. I wanted them to be kind of like Transformers: become a fully operational workshop when I need, but something that I can quickly fold down and easily put away. I am a mum and have limited time to build things, and I don’t like having tools out when little fingers are around.

So, this is the mitre saw station. I hacked a butcher's block I had and built folding wings with a fence that will allow me to add stop blocks. The overall cutting surface is 1.8m which is awesome. Currently, I have shelves but will put four drawers in to hold tools. I love the fact that I can roll out, plug in and fold out my station in less than five minutes.

Tools and materials

Materials used in the project:

• Old rolling butcher's block
  
  
• 4 x 75mm castors
  
  
• 70 x 30mm Pine around the edges to make the sides flush with the top and next to the saw to allow me to add fold up hinges
  
  
• 4 x folding locking hinges 
  
  
• 2 x Okoume 305 x 1200mm panels to fill in the back and sides of butcher's block
  
  
• 2 x 42 x19mm Pine battens split in two to make runners for shelves but eventually drawers
  
  
• 1 x Okoume 305 x 1200mm panels split in half to create the wings
  
  
• 2 x 42 x 19mm Pine battens laminated together to make the back fence support
  
  
• 2 x 600 x 60mm strips of formply to make the front of the fence
  
  
• Kreg Trak and stop kit to sit on top of the fence and allow me to slide on stops. (It also has a measuring tape on each side).

Tools used in the project:

• Mitre saw
  
  
• Table saw or circular saw
  
  
• Drill
  
  
• Driver
  
  
• Kreg pocket hole jig
  
  
• Measuring tape
  
  
• Square
  
  
• Safety gear.

Steps

Step 1

Strip out shelves in old butcher's block.

Step 2

Cut Okoume panels to size to fit back and sides of butcher's block.

Step 3

Cut 1 Okoume panel in half for the wings.

Step 4

Cut 70 x 30mm Pine to size to wrap around the back and sides of cart frame.

 

Step 5

Cut two pieces of 70 x 30mm Pine to the same width as the Okoume wings.

Step 6

Laminate two pieces of 42 x 19 x 1200mm Pine together and clamp.

Step 7

Cut two pieces of form ply or whatever you have on hand to 600 x 60mm for the fence.

Step 8

Trim two of the cart legs to the same length as the other two that already have wheels on them.

Step 9

Sand and seal all timber including butcher's block top. I used Osmo.

Step 10

Drill pocket holes in Okoume panels for the side and back.

Step 11

Attach Okoume panels to side and back between the legs, making sure they are flush with top rail.

Step 12

Attach 70 x 30mm pieces to the side and back so the side is now flush with the top.

Step 13

Split some 42 x 19 x 1200mm (3 approximately) in half so now 21 x 19mm and then cut them to length to act as runners for your shelves or drawers.

Step 14

Attach runners at your desired intervals to create shelves.

Step 15

Cut some 7mm ply to size to act as shelves and attach to runners.

Step 16

Attach butcher's block top back to the top.

Step 17

Add four castors to the legs.

Step 18

Centre mitre saw on the butcher's block.

Step 19

Figure out where to place your wings so your wing fence lines up perfectly with your mitre saw fence and your wings are level with the plate of mitre saw. 

Step 20

Attach the last two pieces of 70 x 30mm Pine to the top of the butcher's block in the position you have marked above.

Step 21

Attach the four folding hinges.

Step 22

Cut your laminated 42 x 19mm Pine in half.

Step 23

Attach Pine to back of wing.

Step 24

Attach form ply fence to wing and Pine backer. Make sure to countersink screws.

Step 25

Take two pieces of the Kreg track stop and drill holes and screw into fence.

Step 26

Clamp wings to fold up hinges and ensure that everything is flush and square.

Step 27

Attach wings to hinges.

Step 28

Add measuring tape to Kreg track stop on either side and attach stops.

More inspiration for your project

Community member Razzer built this 3m long mitre saw workbench with storage, making plenty of extra room in their garage.

Workshop member DonGreen built these saw benches with foldable top, providing more workspace and storage.

Check out our Top 10 most popular garage and shed projects for more creative ideas.