This project was built and designed by Jonny from Jonny Builds. It’s a modular, highly functional miter saw station designed to maximize space, offer generous storage, and increase flexibility in any workshop.
Jonny’s build focuses on creating a mobile setup that includes multiple drawers, cabinets, and a fold-out support wing, all while maintaining a clean, professional look. It’s a practical upgrade for anyone looking to improve their shop layout and workflow.
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Planning the Design
Before cutting any wood, Jonny emphasized the value of planning the station’s layout. The design started with modular components that could easily move around the shop and accommodate cutting longer materials.
SketchUp was used to draft the initial plans, helping visualize both the miter saw station and the accompanying storage. Jonny designed the station to work perfectly with his Metabo HPT miter saw, which adds further flexibility thanks to its cordless and corded options.
Constructing the Cabinets
The main body of the miter saw station is made up of two primary cabinet units: a miter cabinet and a stationary cabinet. Jonny selected three-quarter-inch Baltic birch plywood for durability and a clean appearance.
Panels were cut to size using a track saw and table saw setup. Pocket hole joinery made the cabinet assembly quick, strong, and beginner-friendly, even if a few pocket holes were visible in hidden areas.
Throughout the assembly, clamps were used to maintain squareness and prevent shifting during drilling. Attention to alignment helped make later steps like installing drawers and doors much easier.
Building and Installing the Drawers
Jonny crafted five drawers using half-inch Baltic birch plywood. Each drawer was assembled using pocket holes and secured with quarter-inch plywood bottoms attached by brad nails and screws.
To make the drawers operate smoothly, full-extension drawer slides were installed. Using a drawer slide jig ensured consistent positioning and saved time during installation, resulting in a clean and professional fit.
Adding Cabinet Doors and Fronts
The cabinet doors and drawer fronts were crafted with visual appeal in mind. Jonny opted for a continuous grain pattern across the fronts, a small design touch that gives the whole piece a more polished look.
Euro-style concealed hinges were installed using a hinge jig, allowing for precise adjustments and ensuring the doors opened and closed smoothly. The consistent alignment added to the station’s professional finish.
Mobility and Flexibility
Mobility is a key feature of this build. Heavy-duty casters were added to the base of the cabinets, allowing the entire station to roll easily across the shop floor.
This mobility makes it simple to reposition the saw station when working with long pieces of lumber or adjusting shop layouts. It also helps maximize usable floor space, something every woodworker appreciates.
Building the Fold-Out Support Wing
The fold-out wing is one of the standout features of the station. Inspired by designs from other woodworking channels, this wing provides additional material support when needed but folds down to save space when not in use.
Pocket holes were used to assemble the support frame, ensuring strength without bulky hardware. Heavy-duty hinges and a support block were added to keep the wing level and stable during use.
Installing the Fence and Track System
Once the main structure was complete, Jonny moved on to installing the fence system. A straightedge was used to ensure perfect alignment, which is critical for maintaining cutting accuracy.
A track system was incorporated to allow for repeatable cuts, a huge timesaver for anyone batching out parts or needing consistent dimensions. The track was easy to install and made the station even more versatile.
Finishing Touches
Before finishing, the entire structure was sanded smooth to remove any splinters and surface roughness. Jonny added a personal touch by painting the drawer pulls in bright colors, proving that even shop furniture can have some character.
For protection, a spar varnish was applied in multiple coats. This finish not only enhances the look of the Baltic birch but also protects the station from shop wear and tear over time.
A Workshop Upgrade Worth Building
This mobile miter saw station is a great example of how thoughtful design can make a workshop more efficient. The combination of ample storage, modular mobility, and a sturdy fold-out wing makes it ideal for both small and larger workspaces.
Jonny’s focus on practical improvements without overcomplicating the design makes this project accessible for a wide range of woodworkers. It’s an investment of time that pays off in daily convenience and improved workflow.
Get Jonny’s plans here: https://www.jonny-builds.com/miter-saw-station.