How to Set Up a Cutting Station for a Radial Arm Saw

A radial arm saw is similar to a circular saw that is suspended on a movable arm. The arm is able to be adjusted for different degrees and bevels to make compound miter cuts. A radial arm saw can be a valuable tool in your shop when set up for accurate cuts through the use of a cutting station. The do-it-yourself handyman can build a radial arm saw workstation for his woodworking shop using standard woodworking tools.

Things You'll Need

• Radial arm saw
• 3/4-inch plywood
• Caster wheels
• Nuts and bolts
• Electric drill with bit
• Cabinet doors
• Shop vacuum
• Power screwdriver
• Piano hinge
• Wood screws
• Table saw
• Tape measure
• Pencil
• Straight edge
• Circular saw
• "L" bracket
• 2-inch carriage bolts
• Wrenches
• Wood glue
• Nail gun

Instructions

1. Build a cabinet that matches the width of the radial arm saw's table. The cabinet's height should be 35-1/2 inches. Place a 3/4-inch piece of plywood on top on the cabinet. Subtract the height of the caster wheels if you want your workstation to be mobile. Also subtract the height of the radial arm saw from the top of the table to the bottom of the saw's frame without the legs. Using 3/4-inch pre-finished plywood works best for the cabinet.

2. Attach the radial arm saw to the top of the cabinet using nuts and bolts. Ensure that it is aligned with the cabinet's outside edge. Use a drill to pre-drill holes for the bolts through the plywood.

3. Install a set of doors on the front of the cabinet. This will provide a space for a shop vacuum that can eliminate dust. A power screwdriver works best for installing the doors.

4. Cut two pieces of plywood that are the depth of the cabinet to 30 inches long. Attached these to the cabinet using a piano hinge and screws so that they are flush with the top of the cabinet. These are the supports for the in-feed and out-feed tables that you will build later. A table saw and power screwdriver work well for this.

5. Cut two more pieces of 3/4-inch plywood at the same dimensions in the previous step. Measure 6 inches in from the side and the bottom edges and mark with a pencil. Use a straight edge to connect the two points that will provide a cut-line for you to follow using a circular saw. Attach these two pieces to the front of the cabinet using piano hinges. Screw the hinges into the side that was not cut on the plywood. The top of the plywood should be an inch below the bottom edge of the support table from the previous step.

6. Attach a 3-inch "L" bracket at the top edge opposite the hinge of the two pieces of plywood so that it is even with the top. Use nuts and bolts to secure it in place. Place a nut on a 2-inch carriage bolt about half an inch from the top. Put the carriage bolt through the top of the "L" bracket and secure it in place with the lock washer and nut. This provides an adjustment to level the support tables with the top of the cabinet. A pair of wrenches work well to tighten the bolts.

7. Build two 36-inch-long open-ended boxes to sit on top of the support tables. The height of the boxes need to be the distance from the top of the support table to the top of the radial arm saw table. The width will be the same as the support table's top. Attach these to the support table's top with 1-1/2-inch wood screws.

8. Cut two pieces of 3/4-inch plywood 2 inches wide by 36 inches long. Cut two more pieces of the plywood 3 inches wide by 36 inches long. Glue and nail one of each of the two pieces together making a "L" shaped fence. Attach this to the top of the open-ended boxes on each side of the saw using wood screws. Use a long straightedge to align them with the fence of the radial arm saw.

Tips & Warnings

• Wax the top of the radial arm saw tabletop and the out-feed and in-feed support tables and fence with a good paste wax.

• Wear safety glasses and hearing protection when using power tools.

References

• Sawdust Making: Radial Arm Saws
• Craftsman: Radial-Arm or Power Miter Saw
• Mike From Winton: Miter Saw Station