Have you ever wanted a nice wood shop table saw workbench and a router table all in one?  Today I want to show you a table saw workbench that I designed to help bring some order to my little workshop. (Remember how we showed you the mess that we started with last week?)

To help organize this project of ours, we partnered up with Rockler Woodworking and Hardware.  They have so many good options for keeping a shop in order and many great tools for building projects.  We are excited to partner up with them for this very reason.  I will show you all the great tools that I have now because of them, and how it is making my garage shop experience so much better. You saw a sneak peek of this table last week, and  I am so excited to show you how I built the workbench in today’s post.

DIY Router Table and Table Saw Workbench Building Plan #remodelaholic

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I have always wanted to build a big table saw workbench.  It has been years in the making in my head and now finally coming true to life.  It is a large central table that I will use for almost everything.  The work table has the table saw and router table built in.  It would also include a vice and many options for clamping for working on projects.  It’s going to organize and store tools as well.  It is going to be AWESOME POSSUM!!!

The Design of the Table Saw Workbench

I really wanted the table to be multi functional and have many useful features.  I wanted it to be “pertty good looking” as well.  (Thanks Pedro!)  Chances are we will be filming lots of projects from this workbench.

The space where I wanted to keep it is big enough for a 4′ x 7′ workbench surface.   That is pretty big for a work bench.  You can do a lot on a large surface like that, and you can store a lot underneath it as well.

I did a bunch of research of what other people were doing and tried to create the best option for my needs.  Listed below are all of the features that I wanted the table saw workbench to have.

Build A Table Saw Workbench With A Bench Vise, Rockler T Track System, Router Table, And Plenty Of Storage! Free Building Plan #remodelaholic

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Features of the Table Saw Workbench

  • Look amazing!!! That should be obvious right!
  • Sturdy and strong with a 1 1/2″ thick table top.
  • 3″ table top lip over hang for clamping to table
  • Caster wheels to move it around the shop and locking in place.
  • Built-in table saw with outfeed area.
  • Built-in router lift and router fence.
  • T-track system for clamping and building projects.
  • Bench vise for more clamping of projects.
  • Storage for tools with doors to keep the dust out.
  • Leg room when working at the bench sitting on a stool.
  • Place to store a bench or two when not in use.
  • Dust collection area for under the table saw.
  • Improved shop lighting when working on projects.
  • Comfortable floor mats for standing areas around the table and table saw.

It took about a three full days to build and finish it.  I am so pleased with how it turned out and how useful it has been so far. Here are some closeups of the table top features of the table saw workbench.

This is the awesome router table that I now have. It features a fence that slides back and forth in the T-Track and is easily removed for an entire table of flat surface to work on.

Router Lifter with Sliding Track on Rockler T-Tracks | DIY Router Table and Table Saw Workbench Building Plan #remodelaholic

A really big stop switch attached to the router for better safety while routing.

XL Router Stop Button for Safety | DIY Router Table and Table Saw Workbench Building Plan #remodelaholic

A sweet bench vise.

Built-in Bench Vise | DIY Router Table and Table Saw Workbench Building Plan #remodelaholic

Tons of room for using the T-Track clamping system with all the different ways to clamp projects.

Rockler T-Track System for Clamping | DIY Router Table and Table Saw Workbench Building Plan #remodelaholic

Lockable heavy duty casters.

Table Saw Workbench @Remodelaholic 8

Bench storage and floor comfy floor mats.  Why not be comfortable in your work space right?

Tool Storage Under the Work Surface | DIY Router Table and Table Saw Workbench Building Plan #remodelaholic

Oh and this cord reel has been amazing to use.  It’s heavy duty and 30′ long.  It also locks in place if you only need ten feet.  It really cleans up the shop being able to retract a power cord back up in a nice neat reel.

Retractable Power Cord Storage | DIY Router Table and Table Saw Workbench Building Plan #remodelaholic

List of Products from Rockler.com Used in the Post

As we said, we love working with Rockler because of their amazing products! FYI these are affiliate links, which means if you click and purchase through these links, we receive a small commission that helps fun us creating new projects and videos like this —  I really love these products, so I highly recommend them!

Workbench

Clamps

Lighting

Floors

Power Cords

Dust Collection Hoses

DIY Table Saw Workbench Featuring Rockler T Track System, Free Building Plan And Tutorial #remodelaholic

Build Your Own Table Saw Workbench

Now I will show you how to make your own.  Below you will find the plans, tools, materials, cut list and steps of how to make your own table saw workbench.  The only thing that might be different in your plans would be the type of table saw that you would use to build it in.  Mine was a fifteen-year-old Delta table saw.

You could even leave out the table saw and just build the table if you like.  There are many options here.

Click Here to Get a Printable Version of This Building Plan

Plan Dimensions

Free Printable Building Plans | DIY Router Table and Table Saw Workbench Building Plan #remodelaholicTop View, DIY Router Table and Table Saw Workbench Building Plan | Free Printable Building Plans #remodelaholic

Top View

Front View, DIY Router Table and Table Saw Workbench Building Plan | Free Printable Building Plans #remodelaholic

Front View

Side View, DIY Router Table and Table Saw Workbench Building Plan | Free Printable Building Plans #remodelaholic

Side View

 

Tools List

Here are the tools that I used to build the table.

  • Table saw
  • Circular saw
  • Plywood circular saw blade
  • Jig saw
  • Miter Saw
  • Drill
  • Router for T-Track tracks
  • Power chord
  • 3/4″ diameter router bit
  • Sockets for lag bolts
  • Sander
  • Sand paper 120 and 150
  • Brush for polyurethane
  • Rags for dusting
  • Pencil
  • tape measure

Workbench Materials List

Be sure to use cabinet grade plywood or better quality for flatness and select all your wood that is as straight as possible.

Cut List

  • (1) 78″ x 42″ x 3/4″ – Plywood Base
  • (6) 4×4 x 29″ – Legs 
  • (3) 2×4 x 35″ –  Short Support Beams
  • (2) 2×4 x 36 3/4″ – Long Support Beams
  • (1) 78″ x 29″ x 3/4″ –  Middle Plywood Partition
  • (2) 84″ x 48″ x  3/4″ – Plywood Workbench Top
  • (1) 40″ x 24 3/4″  x 3/4″ – Table Saw Shelf
  • (2) Varies depending on height of your saw- Table Saw Shelf Supports
  • (2) 12″ x 4″ x 3/4″ Bench Vise Blocks

Instructions to Build the Table Saw Workbench

Part 1: Build the Workbench Base

Cut the plywood base to length and width.  (78″ x 42″)

Step 1, DIY Router Table and Table Saw Workbench Building Plan | Free Printable Building Plans #remodelaholic

Cut six 4×4 legs to length (29″).Step 1, DIY Router Table and Table Saw Workbench Building Plan | Free Printable Building Plans #remodelaholic

Cut two 2×4 short support beams to length and drill two pocket holes in ends (34″).Table Saw Workbench @Remodelaholic 3

Assemble three leg assemblies of 4×4 and 2×4 support beams with 2 1/2″ pocket hole screws and set upside down.Table Saw Workbench @Remodelaholic 6

Attach the plywood base to leg assemblies with 1 1/4″ wood screws.  Keeping the legs square to the outside corners and centering the middle leg assembly to the plywood base.Table Saw Workbench @Remodelaholic 7

Attach four locking casters on the four corners through plywood base into 4×4 legs.  Predrill the holes to avoid splitting.  Attach two swivel casters in the middle.  Use four lag bolts per caster and add a lock washer and a washer to each lag bolt.Table Saw Workbench @Remodelaholic 9

Flip table over and attach long beam supports between leg assemblies with pocket screws.Table Saw Workbench @Remodelaholic 10I was able to clamp a block of wood under the long support to hold it flush with the top of the leg assemblies.Table Saw Workbench @Remodelaholic 11Here is how the supports look finished.Table Saw Workbench @Remodelaholic 13

Cut out and install middle plywood partition (78″ x 29″).Table Saw Workbench @Remodelaholic 12

Cut out the top corners where the end beams and middle beams are with jig saw.  I cut them 1/8″ bigger than the 2×4 so I had enough room to get the partition in easier.Table Saw Workbench @Remodelaholic 14

Install middle plywood partition to the long support beams on the table saw side with 1 1/4″ wood screws.  Below I am screwing the partition in to the bottom of the table.  You will also be able to screw into the top support beam as well.Table Saw Workbench @Remodelaholic 17

Cut out plywood workbench top pieces and attach with screws (84″ x 48″).

Attach the first layer of plywood workbench top to the top of the legs and beams and screw in place with 1 1/4″ wood screws.  Be sure the center it with a 3″ overhang on all sides.Table Saw Workbench @Remodelaholic 18

Attach the second plywood workbench top the the top of the first plywood workbench top with wood screws from underneath.  (Be sure the keep screws out of the path of the router channels for the T-Track.)Table Saw Workbench @Remodelaholic 19At this point the table is all built and ready to use.  I am taking it further though to add all the other goodies to it.

Part 2: Table Saw Hole and Shelf Preparation, Miter Lift Preparation

Cut out table saw hole with circular saw and jig saw.  Measure out the size of your table saw top and cut it to fit that size.

Use tape to protect the edge of the plywood.Table Saw Workbench @Remodelaholic 20Table Saw Workbench @Remodelaholic 21

Cut out and build table saw shelf 

Cut table saw shelf to length and width (40″ x 24 3/4″).

Workbench Model Steps 10.0 Table Saw Shelf And Supports

Cut out corners to wrap around the legs.  Add 1/8″ to the leg thickness of 3 1/2″, to give room to install it without being too tight.Table Saw Workbench @Remodelaholic 23

Cut out table saw shelf supports.

Assemble shelf and supports with screws.  I used these awesome corner clamping jigs for holding the supports in place while I screwed them together with 1 1/4″ wood screws.Table Saw Workbench @Remodelaholic 24

Cut out hole for table saw dust to fall into.  This hole is 3/4″ smaller than the base of the table saw.  That way the table saw still has something to sit on.Table Saw Workbench @Remodelaholic 27

Attach shelf to table with 1 1/4″ wood screws.  I jacked up the shelf and clamped it in place so I could screw it in underneath.  I also squared it off and screwed it in through the partition.Table Saw Workbench @Remodelaholic 29

Rout out miter gauge outfeed channel in workbench top.  Rout it long enough to get the miter past the blade of the table saw.Table Saw Workbench @Remodelaholic 33

Part 3: T-Track Preparation and Installation

Route out T-Track channels over the entire table at 3/8″ deep.  You want the channels to be deep enough to keep the top of the T-Track flush or just below the surface of the table top. See top view of table for layout of channels.Table Saw Workbench @Remodelaholic 35This is where the T-Track intersections will go.
Table Saw Workbench @Remodelaholic 40

Router Lift Preparation

Cut out router lift hole with router at the depth of the lift plate.  Just slightly bigger than 3/8″ deep.Table Saw Workbench @Remodelaholic 36 Start routing in the middle and work your way around in circles until you get to the edges.  At the edges I clamped down wood as bumpers to keep my lines nice and square.Table Saw Workbench @Remodelaholic 37

Sand and polyurethane table top.  I sanded with 120 grit sand paper.  I also rounded all the corners by hand so they wouldn’t be so sharp.  On the outside edges I used an orbital sander to remove all the print on the boards and level the two top layers together.  Table Saw Workbench @Remodelaholic 41After I sanded I brushed in four layers of scratch resistant polyurethane.  I also sanded with 150 grit sand paper between coats.  I wanted it to be a really nice smooth surface.Table Saw Workbench @Remodelaholic 42

Now it’s time to install the T-Track.  I started with the intersections then cut the T-Track to length with a metal blade on the jig saw.  this part was fu because it was all coming together.Table Saw Workbench @Remodelaholic 43

Part 4: Table Saw Installation

Level the table saw with shims.  I gave myself some wiggle room to be able to shim it up to the right height of the table top.Table Saw Workbench @Remodelaholic 46 I got it nice and flush with the top.Table Saw Workbench @Remodelaholic 32

Part 5: Router Lift Installation

Install router lift adjustment screws.  I installed four of these adjustable screws around each corner of the router lift for fine tuning the lift to the table.  I had to go to the hardware store and pick these up.  Once these are installed, all you need to do with this screw is reach under the table to level out the router lift flush with the top of the table.   You should only have to do this once when you first install the lift.Table Saw Workbench @Remodelaholic 48Here is a picture of the screws and how they are installed.  Drill a hole for the nut and screw it in with an Allen wrench.Table Saw Workbench @Remodelaholic 60 Then reach under and make the fine tunes adjustments to the level of the lift.Table Saw Workbench @Remodelaholic 61This is a longer version of the two screws that came with the lift.  Because the table was 1 1/2″ thick, the screw that came with the lift was too short.  I added the nut to a longer screw that matched.  The nut gets hammered into the bottom of the table, so it would clamp the lift on really tight.Table Saw Workbench @Remodelaholic 49This is how it ended up.   Nice and flush.Table Saw Workbench @Remodelaholic 50

Part 6: Bench Vise and Bench Vise Block Installation

Install vice with 1 1/4″ wood screws to the base of the workbench table top.  I clamped the vise in place and pre-drilled the holes to make it easier to screw in. Table Saw Workbench @Remodelaholic 54

Build a block for the the vise.  Cut out two blocks of wood at (12″ x 4″).  Glue them together.Table Saw Workbench @Remodelaholic 51  Drill three holes for the three bars of the vise to slide through.  Sand and polyurethane the block.Table Saw Workbench @Remodelaholic 52

Remove the two big nuts at the end of the vise.  Install the block of wood you just made over the three bars of the vise.  Align the block with the top of the table then screw in four big 1 1/4″ wood screws through the black metal vise into the block of wood to hold it in place.  Table Saw Workbench @Remodelaholic 53

Whow! That was a lot of work…  But the thing is, it’s done and ready to use.  I plan on this table lasting FOREVER!

DIY Router Table and Table Saw Workbench Building Plan | Free Printable Building Plans #remodelaholic

Now I need to take the time to find out what tools go where and customize the spaces under the table for them.   I also have plans to build the doors like I mentioned in the design.  I will have to let you know how that goes in the near future.

Thanks for reading this post and stay tuned for more shop updates.

Let me know if you have any good suggestions about how you organize your shop and what has been working well.  I would love to hear your feedback!

We have a bit of a personal problem.  It is being addicted to remodeling… and it spills over into our garage in a very horrible way!

The truth is, since we moved back to Utah 6 or so years ago, we have been actively remodeling 3 separate homes non-stop.  DIY remodeling a house takes A LOT more than a month, it takes a couple years AT LEAST!  This means our tools travel everywhere.  It is like they just sprout legs and walk around at night, think Toy Story… only we’ll call it Tool Story…  Besides the constant shuffling of tools for remodel projects, we are also occasionally creating furniture building tutorials, and/or upcycling or reusing older bits and bobs which has come to a bit of a hording supplies problem.

So basically, what I am trying to say is that our shop is not navigable, meaning you can’t walk in it, let alone, finding what we need at any given moment!  No matter that we have 6 or 7 hammers, we can’t find a single one.

All this to say that the GREAT GARAGE /WORKSHOP MAKEOVER HAS BEGUN!….

The goal is that if Cassity wants to walk into our garage that she will be able to find what she needs because the items have a home.  This idea may sound revolutionary… but I assure, some people in real life have clean workshops… and I want to be one of them.

Here are some views before the clean up.  Sorry If you threw up a little…

Table Saw Workbench @Remodelaholic 1

The blue metal cabinets are actually one of our favorite finds from this house HOWEVER, we didn’t have enough for the space so they are being moved to a new location.  We will love theme there as well!

Table Saw Workbench @Remodelaholic 3

So the goal in organizing the garage is to have a woodshop, but also a place to store Remodeling tools PLUS yard maintenance tools (at least until we get a nice shed!)  This garage used to be a carport.  So the double doors at the back, are the old carport closet.  This space is narrow, yet deep.  So we have 4 ft deep shelves on one side holding our remodeling supplies, like plumbing, electrical, drywall, concrete, tile, and painting supplies.  Each type of projects has big portable plastic bins .  The opposite side houses all our yard tools and extra hoses, gardening tools, rakes and shovels…

 

Table Saw Workbench @Remodelaholic 2

You can’t really see them in the picture above but we salvaged an entire kitchen worth of cabinets from our latest remodel, and those cabinets were stacked in the middle of the garage around the table saw creating a “workbench”.  But with the decision to move out the blue metal cabinets, the old kitchen cabinets will be perfect for a wall counter with TONS of storage…  about 20 feet of all cabinets.

Table Saw Workbench @Remodelaholic 5

You can see how we moved all the kitchen cabinets, along the outer wall of the garage.  Currently they are just sitting in place, but we plan to secure them and update them in the next few months.  But the best thing about organizing the cabinets, is how it opened up the space in the middle of the shop, to really build a nice workbench.  And speaking of the new workbench, let me just geek out about it for a minute..  (plans coming next week)

Table Saw Workbench @Remodelaholic 20

Isn’t it the most beautiful thing you’ve ever seen?  We partnered with an AMAZING store, Rockler Woodworking and Hardware (affiliate link) to build this workbench, and you would not believe all the great little details we’ve worked into it.  Come back next week for the full details of how I built it.

So you can tell that the lighting was improved a lot with the picture above.  I added lots of light.   Let there be LIGHT!!!  This place is flooded with light now.  There is so much light you might be able to see my house from space now!

Can see the little group of three directional light in the picture above?  That is the light that I had before I added the new ones.  It was hard to get a nice even light using spot lights.   I was tired of not being able to see the things I was working on.

So I started to add light in this corner of the garage first.  It was kind of a test to see how many lights I needed.  In this space above the workbench and walls above the cabinets, I was able to get in six 4′ LED lights.   That’s a total of 24000 Lumes in a 120 SQFT space.  The cool thing about these lights is that they link together, with a 4′ chord, up to five lights and they have their own pull chain switch for more control of turning on and off the lights.  Right now I have all the lights plugged in a power switch so they all turn on at once.  It is amazing the difference the lights makes in the shop.  Sometimes I just stand there looking around because the light makes it look so nice.  It makes me want to keep things clean around here.

The floor needed a little attention as well.  They are stained and dirty looking from years of use.  I wanted to cover up the nastiness with some nice foot mats to help clean up the look and provide a comfortable surface to stand on while making projects.  Maybe some day I will be able to apply some really nice concrete floor paint over the entire garage to make it all look good.

Table Saw Workbench @Remodelaholic 6

One thing that is always present in a woodshop is the saw dust.  I’m excited to look into some better practices of dust collection and to see what Rockler has to offer.  I will have to be better at cleaning up everyday that’s for sure.

I’m pretty sure Cassity just might be able to find something in the garage next time she comes into the garage.  There are still a TON of things on the to do list.  And with it being summer and the kids are home, it may take us a bit of time to wrap up everything, but we are learning patience and just starting with the main workbench has been a huge motivator to get the rest of the space done!

Please come back next week to see more of how I actually built the workbench and the cool features that I designed into it.