How to Build a Table Saw Workstation & How to Cut Plexiglass on a Table Saw?

table saw workstation

How to Build a Table Saw Workstation?

Making a table saw workstation is neither easy nor hard. If you want to make a table saw workstation, then follow the instruction given below. Hope, you’ll able to make a perfect workstation for your work successfully. Let’s start-

Step 01- Sub-frame:

The first step of building a table saw workstation is to set up a sub-frame. The entire sub-frame is generally built with a 2×4 lumber. The sub-frame is the basic structure of the workstation so you should make it carefully and ensure that it’s strong enough to serve well. You may also use square lumber.

Step 02- Surface:

The surface of a table saw workstation is very important as you have to cut the wood pieces on it. ½ inch melamine and ¾ inch shop grade birch work fine usually as the workstation surface. But the Baltic birch is quite well for making the surface and comes with less ply than the shop grade birch. And for the melamine, you can also replace it with anything hard material. But using metal plates isn’t a good idea.

Step 03- Fence Layout:

A solid and square shaped fence layout is always better for a table saw workstation. The fence is found in almost every contractor table saws. You can replace the fence layout with metal. Using a metal of 3/16 inch thickness works fine as a fence layout. And if the funds allow, then we’d like to recommend you to get an aluminum extrusion. It’ll be the best if you place it for the actual fence rail and main side rail.

Step 04- Alignment:

After the fence layout, it’s important to build up a support in order to hold the fence in position. Though the fence of a table saw look so complicated, it’s easy to reproduce it. Make a strong alignment to hold the fence. Get a clamp set (70 odd, 3/16 inch of length steel is good enough) to make the strong alignment. Remember, it’s required for safety too.

Step 05- Cutting:

The main purpose of making a table saw workstation is to cut the wood pieces or material smoothly and better. Place a sacrificial wood piece along with the side of the saw fence. This is a great way to prevent inadvertently cutting into the metal fence. Additionally, this trick helps a lot to cut smoother and let the fence flush to be brought, with the table surface. Place it 1/16 inch above the saw table.

And your table saw workstation is now complete! Have fun.


How to Cut Plexiglass on a Table Saw?

Not only wood pieces, but you can also cut the plexiglass on a table saw. The table saw is probably the most stable and easiest tool to cut a plexiglass. The plexiglass is mainly a kind of plastic. That’s why there is a possibility that the glass may melt during cutting. So, don’t cut it so fast, try in slow motion. Let’s read out the steps to cut a plexiglass on a table saw-


Step 01- Measure the Plexiglass:

You must measure the thickness of the plexiglass before start cutting. That’s because if the plexiglass that you want to cut is quite thin, then it’s better not to try out cutting it on the table saw. You may chip the plexiglass. You can use a utility knife for this job. Proceed with the table saw only if the plexiglass is ¼ inch or up in thickness.

 Step 02- Get the Right Saw Blade:

The plexiglass is both soft and hard for cutting. Soft plexiglass melts so easily. To avoid melting, try out the blade which has fewer teeth in order to reduce total friction during cutting. And for the hard plexiglass, you can use the blades with more teeth in order to keep the chipping in the minimum rate. When you have a lot of different plexiglass to cut, try to cut the same type first. Then change the blade and cut another type. It saves your time and effort as you need to change the blade just once or twice.

Step 03- Measure the Cutting Size:

As like as the wood pieces, you should first the measure the cutting size of the plexiglass and mark that to do the job perfectly. Adjust the fence at the right setting and lock it down. Then start cutting.

Step 04- Ensure Safety & Proceed:

You must ensure your safety first. Always wear safety glasses and gloves before starting the table saw, especially when you’re about to cut a plexiglass. That’s because small shards of the plexiglass fly during cutting and I’m sure you don’t want to end them up in your eyes. After ensuring your safety, proceed to the work.

Step 05- Start Cutting:

After setting everything, turn on the power of the saw and feed the plexiglass slowly and gently through the blade. Use a wooden safety guide during cutting very thing piece in order to keep your hands safe. If the plexiglass melt, slow more down and if the chipping occurs, replace the blade with more teeth.

Step 06- Sand Edges:

After cutting the plexiglass, the edges of the glass become very sharp and can harm you. Use a sandpaper and polish the edges to make them smooth. Remember, cutting the plexiglass on a table saw is very easy, but you must have the proper tools.


How to Remove Rust from Table Saw

It’s really important to remove the rust from your table saw in order to keep the performance and get longer service from the machine. Cleaning the rust keeps the table saw workable. That’s why you need to clean out the rust regularly. But you know what; there is a procedure. You need to follow that to remove the rust completely and perfectly. Here is the method that shows how you can remove the rust from your table saw and it never comes back.

Well, to remove the rust, the first step of the process is to access the situation. If the rust is light & superficial, then it’s easier to clean it up and won’t take a long time. But if the rust appears for years and becomes deep & substantial, then you need to be worried about a little! Yes, a little; because it still can be cleaned out. You won’t get the smooth and precise surface of the table saw when it was new, but you still can get a workable preference as well.

First of all, resist the urge with a sandpaper along with lubricant or mineral oil (WD-40 can be considered too). You may also consider synthetic kitchen scrubbing pad (DO NOT use steel wool, it’ll damage the surface). Use the lubricant or oil amount in the range that you really need, don’t use excess. Wipe out the lubricant or oil once the scrubbing is done. You can try random orbital sander while scrubbing the heavy rust to get a better result.

Once the rust is properly removed, you should look at steps so that the rust never comes back. You’ll get a lot of commercial rust products that give protection against rust. You can get one and apply it to the surface of the table saw so that the rust can’t come again. On the other hand, you can consider paste wax too.

Please note, I don’t know you will believe or not, the old plain distilled vinegar can be also used as a rust inhibitor. It maybe seems like an old tale, but trust me; it works. Apply the vinegar. It’ll help to clean up the last little bit of rust, in case if you missed. After then, apply the final protector or lubricant and wipe it out. You’ll table saw surface is now protected. Good luck.



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