Table Saw Workbench Building Plans with Rockler T-Track System

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.

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DIY Router Table and Table Saw Workbench Building Plan #remodelaholic

Table Saw Workbench Woodworking Plans

 

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!!!

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UPDATE: See how we upgraded the table saw fence!

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.

See how I used the table saw workbench to build a two-in-one Hoosier style bar stool step ladder to use while I’m working at the bench and around the garage and also our entry table with cubbies (that can also be a changing table).

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. (And you can make yours a full 8 feet if you prefer.)

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

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.

Want to know how the workbench is holding up? See our 3-year update post here for what we love and what we’d change. 

Built-in Router Lift and Router Fence

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

Safety Feature: Router Stop Switch

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

Workbench Bench Vise

A sweet bench vise with quick-release is always handy.

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

T-Track Clamping System

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

Movable with Heavy Duty Locking Casters

Lockable heavy duty casters let me move it when I need it, but hold it very secure when I’m working.

Table Saw Workbench @Remodelaholic 8

Workbench Storage Space

Bench storage (and see my new Hoosier step stool setup here) and 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

Workbench Cord Organization

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 us create new projects and videos like this —  I really love these products, so I highly recommend them!

Workbench

Fence I upgraded to (details here):

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 table saw workbench, including  the woodworking plans; tools, materials, and cut list; and step by step instructions 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.

Or click here to go right to the checkout.

Plan Dimensions

Free Printable Building Plans | DIY Router Table and Table Saw Workbench Building Plan #remodelaholicTable Saw Workbench Top View Updated Dimension For T Track

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

Get the full printable plans here. 

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 fun 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!

More woodworking plans:

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61 Comments

  1. Can you tell me what kind of 4×4 wood you used. I have been everywhere around me and can only find treated lumber or cedar post.

  2. Love the plan! Does the base have enough strength? Seems to me with only the plywood bottom base, and no cross bracing, there would be some bend in the plywood.

    1. I have not seen any bend in the plywood base. If you are concerned you can always add under the plywood some 2×4 bracing on it’s edges. I had plans at one time to add a simple rectangular frame under the base for added support. Thanks for asking.

  3. I really like the table, purchased the plans to make one. I don’t see an actual router just the lift. What kind of router works with the lift?

    1. I use a ridged but it didn’t quite work the way I needed with the collar I bought for it. I had to make my own collar. But it is hard to get in and out. I need to explore other router options.

  4. Great looking bench, and lots of great functionality! I have searched for some time and keep coming back to this one as the most viable for my space, with some minor modifications (for example, I have an older Craftsman table saw with external motor, which will require a different solution for the center support in that area – not a major issue). The main question I have is about the casters. Do you feel any movement or instability when you’re working on clamped pcs or pushing hardwoods through the table saw, etc. or would you consider a retractable caster if you were doing it again? Thanks for sharing!!

    1. The casters I have lock down really firm. I have not noticed any movement when I push things through. It’s also hard to move if I am trying to just push it over just an inch. They are great casters in my mind.

  5. how did you deal with the fact that the rear fence rail is omitted? i supposed it would be possible to include it my having a gap behind the back of the saw top. even the new fence that you want has a rear rail for the back of the fence to ride along and to keep the fence level.

      1. I used Biesemeyer T-square Commercial Fence System. Left off rear rail because table is too deep. Works great.

      2. I also had to attach the front rail to the table and not the table saw. A little tricky but it works.

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