How To Make A Table Saw With A Skill Saw: Save Money!

Can I make a table saw with a skill saw? Yes, you can! Building a table saw from a circular saw, sometimes referred to as a skill saw, is a cost-effective alternative to buying a dedicated table saw. This project, involving a skill saw table conversion, allows you to perform accurate cuts and enhance your woodworking capabilities without breaking the bank. This comprehensive guide will walk you through the entire process, offering practical advice, safety tips, and clear instructions. We’ll cover everything from choosing the right materials to fine-tuning your homemade table saw jig.

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Why Build a Table Saw From a Skill Saw?

There are several compelling reasons to consider converting a circular saw to a table saw, this budget table saw project appeals to many woodworkers:

• Cost Savings: New table saws can be expensive. By utilizing a circular saw you already own (or acquiring an affordable one), you can significantly reduce your initial investment.
• Space Efficiency: If you have limited workshop space, a DIY table saw from circular saw can be more compact than a full-sized table saw.
• Versatility: While not a replacement for a high-end table saw, a well-constructed skill saw table mount can handle a variety of woodworking tasks.
• DIY Satisfaction: Building your own tools is a rewarding experience that enhances your understanding of woodworking principles.
• Portability: In many cases, a homemade table saw jig can be easier to transport than a standard table saw, making it ideal for job sites.

Planning Your Skill Saw Table Conversion

Before you begin building your circular saw table saw alternative, careful planning is crucial.

Assessing Your Circular Saw

• Saw Size and Power: Choose a circular saw with sufficient power for your intended projects. A 7 1/4-inch blade is a common and versatile size. Look for a motor with at least 12 amps for adequate cutting power.
• Base Plate Material: Steel or aluminum base plates are preferred, as they are more durable and stable than plastic.
• Spindle Lock: A spindle lock simplifies blade changes.
• Blade Depth Adjustment: Ensure your saw has a smooth and accurate blade depth adjustment mechanism.
• Condition: Make sure your circular saw is in good working condition. Replace worn brushes or bearings before starting the conversion.

Material Selection

• Table Top: MDF (Medium-Density Fiberboard) or plywood are popular choices. MDF is very flat and stable but is heavy and susceptible to water damage. Plywood is lighter and more water-resistant, but may not be as perfectly flat. A thickness of 3/4 inch is recommended.
• Frame: Use sturdy wood like 2×4 lumber or metal framing for the frame. This provides stability and support for the table top.
• Legs: You can use 2×4 lumber or purchase pre-made table legs. Consider adding adjustable feet to level the table on uneven surfaces.
• Fasteners: Use screws, bolts, and wood glue to assemble the table.
• Hardware: You’ll need T-track for the miter gauge slot, blade guard components, and hardware for mounting the saw.
• Rip Fence Material: Wood or aluminum can be used for the rip fence. Aluminum is more durable and easier to adjust precisely.

Essential Tools

• Circular Saw (the one you’re converting)
• Drill/Driver
• Jigsaw or Router
• Measuring Tape
• Square
• Clamps
• Safety Glasses
• Hearing Protection
• Dust Mask
• Wrench set for tightening bolts

Designing Your Table

Consider the following factors when designing your circular saw table plans:

• Table Size: Determine the optimal table size based on your typical projects and available space. A table size of 24×36 inches is a good starting point for many users.
• Table Height: Choose a comfortable working height, typically between 34 and 36 inches.
• Blade Opening: Carefully plan the location and size of the blade opening to ensure accurate alignment with the circular saw blade.
• Rip Fence: Design a rip fence system that is easy to adjust, locks securely in place, and provides accurate cuts.
• Miter Slot: Incorporate a miter slot for use with a miter gauge, allowing for precise angled cuts.

Step-by-Step Guide to Building Your Table Saw

Follow these steps to build your skill saw table:

1. Building the Table Frame and Legs

• Cut the frame pieces to the desired length.
• Assemble the frame using screws and wood glue, ensuring it is square.
• Attach the legs to the frame, using screws and glue. Consider adding bracing for extra stability.
• Attach adjustable feet to the legs.

2. Preparing the Table Top

• Cut the table top material to the desired size.
• Mark the location of the blade opening on the underside of the table top.
• Use a jigsaw or router to cut out the blade opening.
• Install T-track for the miter slot, ensuring it is parallel to the blade opening.
• Consider applying a durable finish to the table top to protect it from moisture and wear.

3. Mounting the Circular Saw

• Create a mounting plate from plywood or metal to attach the circular saw to the underside of the table top.
• Securely attach the circular saw to the mounting plate using bolts and washers.
• Align the blade with the blade opening and T-track.
• Attach the mounting plate to the underside of the table top, ensuring the blade is perfectly centered in the blade opening.
• Test the blade depth adjustment to ensure it works smoothly.

Table: Comparing Mounting Plate Materials

Material	Pros	Cons
Plywood	Affordable, easy to work with	Less durable than metal, prone to warping
Metal	Durable, stable	More expensive, requires metalworking tools

4. Building the Rip Fence

• Cut the rip fence components from wood or aluminum.
• Design a clamping mechanism to hold the rip fence securely in place.
• Attach the clamping mechanism to the rip fence.
• Test the rip fence for accuracy and ease of adjustment.

5. Adding Safety Features

Safety should be your number one priority when building and using a DIY table saw.

• Blade Guard: Construct a blade guard from clear plastic or wood to protect your hands from the blade.
• Splitter: Install a splitter behind the blade to prevent kickback.
• Push Sticks: Always use push sticks to guide workpieces past the blade, keeping your hands a safe distance away.
• Emergency Stop Switch: Consider adding an easily accessible emergency stop switch to quickly shut off the saw in case of an emergency.

Fine-Tuning Your Homemade Table Saw Jig

Once your table saw is assembled, take the time to fine-tune its performance:

• Blade Alignment: Ensure the blade is perfectly aligned with the miter slot and rip fence.
• Fence Parallelism: Check that the rip fence is parallel to the blade.
• Blade Height: Adjust the blade height for optimal cutting performance.
• Testing: Practice making cuts with scrap wood to get a feel for the saw’s operation.

Tips for Accurate Cuts

• Measure Carefully: Always measure and mark your workpieces accurately.
• Use a Sharp Blade: A sharp blade will produce cleaner, more accurate cuts.
• Feed Rate: Control your feed rate to prevent burning or chipping.
• Support Long Workpieces: Use outfeed supports to prevent long workpieces from tipping.
• Featherboards: Utilize featherboards to keep workpieces tight against the fence.

Skill Saw Rip Fence Jig Options and Building Instructions

A rip fence jig is a critical component for achieving accurate and repeatable rip cuts. Here are a few options you can consider:

Simple Wooden Rip Fence

This is the easiest and most affordable option.

Materials:

• A straight piece of hardwood (e.g., oak, maple)
• Two clamps
• Wood screws

Instructions:

1. Cut the hardwood to a length slightly longer than the table’s width.
2. Attach two cleats to the underside of the hardwood to hook over the edges of the table.
3. Clamp the fence to the table at the desired distance from the blade.

Adjustable Wooden Rip Fence

This option offers more flexibility and precision.

Materials:

• Hardwood for the fence
• Two threaded rods
• Wing nuts
• Washers
• Wood screws

Instructions:

1. Build a fence similar to the simple wooden rip fence but include two holes for the threaded rods.
2. Attach the threaded rods to the fence.
3. Create two brackets that attach to the table and allow the threaded rods to pass through.
4. Use wing nuts and washers to adjust the fence’s position.

Aluminum Rip Fence

This is the most durable and accurate option.

Materials:

• Aluminum extrusion (e.g., T-track)
• Clamping mechanism (e.g., quick-release clamps)
• Hardware for assembly

Instructions:

1. Cut the aluminum extrusion to the desired length.
2. Attach the clamping mechanism to the extrusion.
3. Use the T-track to mount the fence to the table.

Detailed Construction of a Basic Wooden Rip Fence

1. Cut the Fence Piece: Choose a hardwood like oak or maple for durability. Cut a piece that’s about 3-4 inches tall and long enough to span the width of your table plus a few extra inches.
2. Prepare Cleats: Cut two smaller pieces of the same hardwood. These cleats will hook over the edge of your table to secure the fence. They should be about 2-3 inches wide and long enough to provide a solid grip on the table edge.
3. Attach Cleats: Position the cleats on the underside of the fence piece, near each end. Attach them using wood glue and screws. Ensure they are flush with the bottom edge of the fence and perpendicular to its length.
4. Secure the Fence: To use the fence, simply hook the cleats over the edge of your table and clamp the fence down. Make sure the fence is parallel to the blade for accurate cuts.
5. Fine-Tuning: Use shims if needed to ensure the fence is perfectly aligned with the blade.

The Importance of Dust Collection

Sawdust is a significant byproduct of using a table saw, and it poses health and safety risks. Implement a dust collection system to keep your workshop clean and safe.

• Shop Vacuum: Connect a shop vacuum to the circular saw’s dust port (if equipped) or to a custom-built dust shroud around the blade.
• Dust Collector: A dedicated dust collector provides superior airflow and filtration.
• Dust Mask: Always wear a dust mask when operating the table saw.

Safety Precautions When Building and Using

• Wear Safety Glasses: Protect your eyes from flying debris.
• Use Hearing Protection: Table saws can be loud, so wear earplugs or earmuffs.
• Never Reach Over the Blade: Avoid reaching over the blade while the saw is running.
• Disconnect Power: Always disconnect the power cord before making any adjustments or changing the blade.
• Be Aware of Kickback: Understand the causes of kickback and take steps to prevent it.
• Read the Manual: Familiarize yourself with the circular saw’s operating instructions and safety guidelines.
• Stay Focused: Avoid distractions and concentrate on the task at hand.
• Use Proper Lighting: Ensure adequate lighting in your workspace.

Common Mistakes to Avoid

• Inadequate Support: Make sure the table frame and legs are strong enough to support the weight of the saw and workpieces.
• Poor Alignment: Ensure the blade, miter slot, and rip fence are perfectly aligned.
• Insufficient Safety Measures: Don’t skimp on safety features like blade guards, splitters, and push sticks.
• Rushing the Build: Take your time and pay attention to detail.
• Ignoring Instructions: Follow the instructions carefully and don’t take shortcuts.

When to Upgrade to a Dedicated Table Saw

While a DIY table saw can be a great solution for budget-conscious woodworkers, there are times when it makes sense to upgrade to a dedicated table saw.

• Increased Project Volume: If you’re consistently working on larger projects, a dedicated table saw will offer greater efficiency and power.
• Higher Precision Requirements: For projects requiring extremely precise cuts, a high-end table saw with advanced features is a better choice.
• Advanced Features: Dedicated table saws often come with features like digital readouts, more robust rip fences, and improved dust collection.

Fathoming Circular Saw Table Plans

There are many available circular saw table plans online, ranging from basic to advanced. Some resources include:

• Online woodworking forums: These forums often feature user-submitted plans and build logs.
• YouTube: Many woodworkers share tutorials on building circular saw tables.
• Woodworking websites: Sites like Instructables and Popular Woodworking offer detailed plans and instructions.

Before committing to a plan, carefully review the instructions and ensure you have the necessary skills and tools.

FAQ

• What is the best size for a DIY table saw table?
  • The best size depends on your needs and available space. A common size is 24×36 inches, but you can adjust it based on your typical projects.
• Can I use any circular saw for this project?
  • While most circular saws can be used, choose one with a sturdy base plate and sufficient power.
• How do I prevent kickback on my DIY table saw?
  • Use a splitter, blade guard, and push sticks. Always keep your hands a safe distance from the blade.
• What kind of blade should I use?
  • Choose a blade appropriate for the material you’re cutting. A general-purpose blade is suitable for most tasks.
• How can I ensure my rip fence is accurate?
  • Use a high-quality rip fence and take the time to align it properly.
• Is it safe to build my own table saw?
  • Yes, if you follow safety precautions and take your time. However, always prioritize safety and be aware of the risks involved.
• Where can I find circular saw table plans?
  • You can find plans online on woodworking forums, YouTube, and woodworking websites.

By following these steps and taking the necessary precautions, you can build a functional and cost-effective table saw from a skill saw, enhancing your woodworking capabilities and saving money in the process. This skill saw table conversion is a worthwhile project for any DIY enthusiast.