In this instructable / video I will show you how I made crosscut sled, rip fence and downdraft box to my previously made workbench.
From simple jigsaw table to very capable small scale woodworking machine - this is how I describe the importance of these accessories.
Before I started designing my workbench, I had no previous experience with woodworking projects of this scale. And now, with all accessories, I have workbench which is build very well and is insanely convenient. I am truly amazed what you can achieve if you put in work.
Free plans of the accessories - http://bit.ly/WorkbenchAccessories
If you want to see how I made my workbench with inverted jigsaw (+free plans): https://www.instructables.com/id/DIY-SmallPortabl...
Router integration and more accessories for this workbench: https://www.instructables.com/id/Router-Table-Jig...
Tools You'll Need:
- Router https://amzn.to/2DVXXZC
- Drill: https://amzn.to/2U5QQmL
- Large drill bit https://amzn.to/2LB5FgQ
- Jigsaw https://amzn.to/2rg4uXx
- Circular saw https://amzn.to/2PaxiKx (optional)
- Straight guide https://amzn.to/2E53wWg
- Speed Square https://amzn.to/2Qat9vz
- Clamps https://amzn.to/2E8EBkQ
- Tape measure https://amzn.to/2rfS4Ph
Materials You'll Need:
- 18mm thickness plywood (local hardware store)
- 6mm thickness plywood (local hardware store)
- Aluminum U shape profile (local hardware store)
- Drainage pipe or any connector to your vacuum (local hardware store)
- Small wood screws (local hardware store)
- Bolts 2x M6x50 (local hardware store)
- Clamping knobs 32mm M6 https://amzn.to/2zBBFcp
- Threaded e-nut M6 https://amzn.to/2rhZCB4
- Window seal tape https://amzn.to/2AnUse9
- Wood wax https://amzn.to/2LGVJS7
- Wood glue: https://amzn.to/2E8Baus
- 30 minute epoxy https://amzn.to/2zA92wi
- Sandpaper https://amzn.to/2M1mUE7
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Step 1: Preview of the Accessories
Step 2: Routing Slots
I started with routing slots for the aluminum tracks for the crosscut sled. They should be perpendicular to the front of the table and of course must be parallel with each other.
Step 3: Placing Tracks
I drilled and countersunk 3 holes for the wood screws in the tracks. Then I marked and drilled pilot holes into the workbench and tightened the tracks with small wood screws. As tracks were too long I just cut them with a jigsaw.
Step 4: Making Crosscut Sled
I first cut few pieces from 18mm thickness plywood for the sled's fence and then glued them.
Step 5: Tracks for the Sled
I cut thin strips for the aluminum tracks. As they were a little bit too thick, I sanded them. And then I cut base part for the sled from 6mm thick plywood.
Step 6: Gluing Tracks
To easily glue strip tracks to the base, I placed small nuts across the aluminum tracks, added wood glue, placed sled's base and added weights. When glue dried up, I trimmed the strips.
Step 7: Trimming, Chamfering
I added tape to prevent chipping and cut into the sled. Then I trimmed fence of the sled to correct width.
I also chamfered inside bottom edge of the fence to avoid inaccurate cuts due to dust buildup.
Step 8: Marking Line for the Fence
I marked line which is perpendicular to previously made cut.
Step 9: Connecting Fence to the Base of the Sled
Then clamped the fence to the base and secured parts with two small wood screws.
Step 10: Test Cut, Waxing
I made test cut, and it looked good so I added two more screws into the sled and waxed workbenches' top and sled's bottom for better sliding.
Step 11: Making Downdraft Box
To make downdraft box, I cut side parts from 18mm thick plywood and for the bottom and top I used 6mm thick plywood.
Step 12: Gluing Downdraft Box
I drilled hole for the shop vac connection and glued all parts except top to form a simple box.
Step 13: Shop Vac's Connector
To minimize friction and wear of my shop vac's end hose, I cut small ring from plastic drainage / sewer pipe, as it has perfect diameter for my shop vac.
Step 14: Top Part of the Box
I marked and drilled holes into top part of the downdraft box. I added painters tape to prevent chipping, but it barely helped. So I just needed to sand it more to get rid of those plywood chippings.
Step 15: Finishing Downdraft Box
Finally, I sanded top of the sides, added window seal tape to prevent air leaks an tightened 4 screws in each corner.
Step 16: Making Rip Fence
To make rip fence I cut two identical parts from 18mm thick plywood. I glued both pieces and clamped them.
Step 17: Cutting Rip Fence's Clamps
I cut more parts for the clamping mechanism and trimmed rip fence to the right length.
Step 18: Making Rip Fence Clamps
I drilled hole, threaded e-nut and screwed bolt into the part which will be sliding along front of the table. I added wood glue and clamped it to the rip fence.
Step 19: Finishing Rip Fence
After few hours I secured both parts with two wood screws. I additionally glued small piece of sandpaper on part which will be holding fence to the bottom of the tabletop. On other end of the fence I did everything the same, except that I left 2mm gap between the edge of the table and the edge of the clamp.
Step 20: Rip Fence Done
I tested these simple clamps and they hold very strong.
Step 21: END
And that's it - the build is finished!
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