Miter saws can be used in a woodworking shop as a permanently affixed tool or on the jobsite as a moveable or semi-moveable unit. I will take a look at the construction of miter saw tables relative to both types of installations.
The rationale of a miter saw table is two-fold: (1) to elevate the saw to a comfortable working height for the woodworker and (2) to provide a surface to the left and/or right of the blade for the extension of the fence and to provide support for long materials while being cut. If you have ever attempted to cut a 45-degree miter at one end of a 2 x 6 x 12, you realize why a miter saw table or roller stand is unquestionably needed.
Very often, miter saws are used to make repeated cuts of the same length. Some sort of saw stop comes in handy and greatly saves production time for this sort of process. A saw stop must mount to something to hold it motionless, usually a fence. You can make your own fence out of a very straight piece of wood or metal or you can do as I did and buy a commercially available moveable stop that slides along an aluminum track that features a stick-on measuring tape.
PERMANENT SAW TABLE FOR SHOP USE
Since I buy boards in lengths up to 14 feet, I decided to make a very long miter saw table in my woodworking shop. You may not have the physical space for this in your shop so you may have to decrease my measurements accordingly. The longer you can build it, the better but any length of saw table is better than no table at all. My miter saw table measures 8 Feet to the left of the saw blade and another 8 feet to the right of the saw blade. This way, I can support the full length of a sheet of plywood on either side.
The saw table is made over 2 x 4 framing and contains multiple storage drawers below the table which I use to store small tools and supplies. If you choose, the area underneath the saw table can be left open for shelf space or wood. I suggest that the top surface be 3/4" Melamine or Formica over 3/4" particle board. If you can use the entire 4-foot width of the Melamine or particle board, by all means do so, especially if your miter saw is of the “sliding compound miter” style. As for overall table level, I would suggest that you make the miter saw table so that the top of the table comes to your belt line when standing. This will give you a comfortable working height and still let you to bend over the table.
There should be a gap cut through the saw table top in the area where the saw is to be mounted. This gap must be exactly as wide as the top of your miter saw and must be open to the front of the table. The gap should close behind the top of the miter saw. The saw must be placed in this gap so that the top of the miter saw table is flush with the top of the saw table. The miter handle must be free to move its full distance in both directions, left to right.
Foresee the need for this gap as you are framing the underside of your miter saw table because you will have to fabricate a shelf underneath to accommodate the weight of the miter saw. You might want to make this shelf variable in micro increments so that you can get the top of the saw platform exactly flush to the top of the saw table. You can do this with lag screws with washers in sliding slots through the shelf rubber hammer before tightening the lags fully. Use a long straightedge in all directions to make sure that the miter saw and the miter saw table are flush with each other. Install the saw securely to the shelf using lag screws.
Once the miter saw is installed, you can begin to fabricate the fence or fences. A simple, inexpensive fence can be made using two 1 x 4 or 1 x 6 clear fir boards. This wood should be hand selected for straightness and jointed on one edge. One piece of wood will be the actual fence and the other will keep it straight from behind. The fence sits with its jointed edge on the saw table top while the back-up board lies flat on the table, to the rear of the fence, with its jointed edge joined to the lowest part of the fence.
Before joining the two boards together, slotted holes should be cut into the back-up board for the purpose of mounting and adjusting the fence position on the table top with reference to the fence on the miter saw. These slots should be slightly wider than the shaft diameter of the lag screws you intend to use to secure the fence to the table. Cut a few equally spaced slots in the back-up board perpendicular (at right angle) to the fence. A 2 x 4 joist should be located under the table top, centered underneath the slots in the back-up board. This will give the lag screws something solid to bite into.
Before attaching the fence or fences to the miter saw table top, draw a pencil or chalk line where the front of the fence is to be placed. Take a long straightedge, lay it flat on the miter saw’s metal table and push one edge of it along the miter saw’s metal fence. Keeping it in this position, draw a pencil line along the table top, out as far as possible. Do this again on the opposite side of the saw if you have tables on both sides of the saw. Extend this pencil line as far as possible.
Place the fence along the pencil line with the end of the wooden fence almost touching the end of miter saw’s metal fence. (Leave a 1/16" gap between the wooden fence and the metal fence. ) Drill accurately sized holes for the lag screws through the table top and into the 2 x 4 joist underneath the table top (one for each slot). Mount the fence to the table loosely so that it can be aligned. Use the long straight edge on the miter saw’s table and on the front of the fence to align the fence seamlessly and screw down tightly. Duplicate this for the other side of the table if there is one.
For the left fence, place a “right to left" reading stick-on measuring tape along the top of the fence. For the right fence, place a “left to right" reading stick-on measuring tape along the top of that fence. Before sticking down, the tapes must be located perfectly. The left tape is measuring the distance from the left side of the saw blade teeth and the right tape is measuring the distance from the right side of the saw blade teeth. With a simple wooden fence like this, you can use wooden stop blocks clamped to the fence with C-clamps for repeated cuts.
A slightly more costly and far better alternative is to use a metal track or tracks with a flip-up stop and measuring tape built in. Such a device is manufactured by Kreg Tools and is available in 4-foot track lengths that can be butted together to achieve longer lengths. My miter saw table requires four 4-foot tracks, two for each side of the saw. The track is mounted to the top of the wooden fence you just made. You will have to adjust the height of the wooden fence (2 1/4"+ 1/16" = 2 5/16" above the table top) so that the bottom of the flip-up stop clears the table by about 1/16" in the down position.
The nice thing about the flip-up stop is that it can be pushed up out of the way without loosing its measurement setting along the measuring tape. If you were making repeated cuts and you had to stop to use the saw momentarily for a different kind of cut, you could return to your repetitive cutting without delay without losing any accuracy.
PORTABLE MITER SAW TABLE FOR JOBSITE USE
A jobsite miter saw table is customarily made with the saw secured to the extreme right end of the table. I have discovered that most miter saw makers construct their metal table surfaces so that they are 3 1/2" above the table on which the saw is resting. A very straight, milled 4 x 4 (3 1/2" x 3 1/2") can be mounted onto the table top, almost abutting the left side of the metal table of the saw. The 4 x 4 should extend out the full length of the supporting table to the left and be mounted to the supporting table.
A fence can be attached to the back side of the 4 x 4. Use a 1 x 6 or 1 x 8 clear fir board for this purpose. As in the permanent table above, the front of the fence must align perfectly with the miter saw’s metal fence. If a wider support surface is needed, a second 4 x 4 can be mounted directly in front of the one with the fence attached to it.
A Kreg Trak system with a flip-up stop can also be used on this portable miter saw table. Just make sure the wooden fence is ripped to the proper height to allow the flip-up stop to clear the table by 1/16”. (Fence is 2 1/4" + 1/16" = 2 5/16" above the top of the 4 x 4. )
As for the support table, I have used a plastic fold-up table from Costco. They come in various sizes to suit your particular need. Or, you can make your own table out of 2 x 4’s and 3/4" plywood. Design it so that the legs can fold up for transportation and storage.
WOODWORKING TOOL REVIEWS:
© 2010 Robert M. Gillespie, Jr.