Dust Buster

Enlarge Image Image Gallery Bill and his innovative saw table. We modified his design a bit to allow the dust hose to connect to the table bottom (see illustrations below).

While it may not be economically feasible to install a sawdust-control system for the entire garage, we can assemble a self-contained sawdust evacuator for one of the greatest contributors of sawdust in the shop: the table saw. And while prices will vary at lumberyards around the country, $60 should be enough for the wood, hardware, glue and paint needed for this project, give or take a few bucks. Throw in a five-gallon, 1.5-horsepower Shop Vac® for around $40, and a dust-free garage is easily worth the price.

MATERIALS LIST

LUMBER
(5) 8'-long Douglas fir 2x4 studs
(1) 5' length of 1"x6" pine (finished 3/4 x 5 1/2")
(1) 30"x 25" piece of 1"-thick marine-grade plywood
(1) 11"x 10 3/4" piece of 1"-thick marine-grade plywood

HARDWARE
Cap screws: (8) 1/4" x 4 1/4" each with a wing nut and 2 flat washers
Carriage bolts: (8) 3/8" x 3 1/2" each with a wing nut and 2 flat washers; (4) 1/4" x 2" each with a wing nut and 2 flat washers; (4) 1/4" x 1 1/4" each with a wing nut and 2 flat washers
Lag screws: (8) 3/8" x 1 1/2; (8) 3/16" x 3 1/2"
Flat-headed wood screws: (16) #5 x 1 1/2"; (8) # 8x3"
Nails: (16) 2d, 3" box nails; (8) 8d, 3" box nails; (24) 2d, 1 1/2" finishing nails

GLUE
(1) 7 5/8 oz. bottle of Elmer's Carpenter's Glue or equivalent
(1) set of epoxy cement (preferably 2-ton strength)

PAINT
(1) pint of gloss enamel
(1) quart of latex flat paint

SHIMSTOCK (OR COPPER TUBING)
24 sq. inches (or 2' of tubing)
*Note: Copper tubing can only be substituted if available in suitable sizes.

Our table saw is located in an end-of-the-garage workshop where space is very limited (it's no more than 5' x 12'). After acquiring a basic no-frills table saw, I decided I needed a saw table that would meet several requirements. First, it had to be comfortable for my 6' 4" height. I also wanted it to be easy to move and fairly easy to dismantle for convenient storage. Most importantly, however, the table had to have a built-in sawdust evacuation Sys tem because the people in my household are allergic to sawdust. In the end I was unable to find a commercially made saw table that met all of these requirements, so I decided to build my own.