Plans for a Mobile Miter Saw Station

Hey, guys!  I’ve partnered with RIDGID Power Tools on an awesome project to make your miter saw perform like a champ.  I’m going to show you how to build a mobile miter saw station in a 2 part build.  I’ll give you a full walk-through and have the miter saw stand plans ready for you too.  This project is going to give your shop workhorse tons of flexibility, plenty of work support, mobility, and a ton of upgrades.  This miter saw table is a great addition to any garage or workshop short on space.  The plan is made to fit the RIDGID R4122 12” Dual Bevel Miter Saw, but the measurements could be modified to fit other miter saws as well.

The Mobile Miter Saw Station is made from 2 sheets of ¾” plywood.  It is 39” tall on 3” casters.  With side wings extended it’s 93” wide and will support just under 4’ of stock on each side, allowing you to make end cuts on 8’ stock with full support.  With wings closed it’s 38” wide and 24-½” deep, giving it a small footprint. It has a spot for a vacuum to control dust and an open shelf for storing workpieces while making repetitive cuts.

There are several upgrades I made to the DIY miter saw stand plan to give it added performance and usability.  You can add some, all or none of these upgrades depending on your budget and preferences.  A basic version built out of common plywood can be made for right around $100.  But upgrades such as better plywood, larger casters, dust collection, an automated vacuum switch, and an aftermarket fence and stop system can make this build a workshop masterpiece.

Before we get started, make sure to follow me on Instagram, Facebook, YouTube and Pinterest to keep up with all my latest builds and free projects!

Here is what you’ll need for the project:

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The build is broken down into 2 main posts.

Mobile Miter Saw Station Part 1:  Base and side wing supports

Mobile Miter Saw Station Part 2:  Side wings, fences, and upgrades

How to Build a Mobile Miter Saw Stand

All parts are ¾” plywood unless otherwise noted and screws should be predrilled and countersunk before installing.  The base is made of 2 sides 32-¾” tall and 3 shelves 24-¾” wide.  The width of the sides and depth of the shelves matches at 23-¾”.  I built the base on a flat sheet of melamine because my garage floor is too wavy.

Assembling the Miter Saw Stand Base

Drill pocket holes on the underside of the left and right edges of the shelves.  Using a right angle and c-clamps or similar, secure the top shelf 1-¾” down from the top of one side using 1-¼” pocket hole screws.

Secure the other side to the top shelf using the same method.

Attach the middle shelf to each side  5-¾” down from the top shelf.  Using a bar clamp to hold the sides together is useful here.

Screw the bottom shelf in place flush with the bottom of the sides.

Check the miter saw cabinet for square by measuring from corner to corner, first from the bottom right to top left and then from the top right to bottom left.  The cabinet is square when the measurements are equal.

Cut a back piece approximately 31” by 26-¼” to overlap the sides, top shelf and bottom shelf.  Measurements may vary depending on your plywood.  Tack the back in place at two corners with a 18ga Brad Nailer and then secure with 1-¼” screws around the edges.

If you will be adding dust collection to your DIY miter saw stand, drill holes for the vacuum hose and the power cord in the back.  I drilled a 2-½” hole for the vacuum hose and a 1-½” hole for the power cords.

Flip the cabinet upside down and mount the casters on the bottom corners.  Use 1-¼” screws into the sides and back and ⅝” screws when attaching only to the bottom shelf.

You’ve finished the base, way to go!

Making the Miter Saw Station Side Wings

Next you’ll make and attach the side wing supports for the DIY miter saw stand.  Cut a piece to 37-¼” by 23”.  Make a diagonal cut from 4” in from the top to 4” in from the bottom as seen in the picture.  I used a 5” spacer (the width of my Gen5X base plate to the blade) to position a straight edge for the cut.  Cut the triangular end off each piece off to make them 28” long.  

Cut two 5” by 2” support riser pieces.  These will hold 2-½” hex head bolts and wing nuts used to level the side wings.  Drill a ⅜” hole 2” deep centered on the top of the support riser.  

Using a hex wrench, screw in a ¼”-20 x 20mm insert nut into the ⅜” hole.  Install the hex bolts and wing nuts.  The insert nuts, wing nuts and bolts are available in the hardware section at your home center.

Attach the support risers to the side wing supports with glue and 1-¼” screws.  The risers should stick up 1” past the side wing supports and be flush with the outside edge of the side wing support.

Using a hacksaw or a reciprocating saw with a metal blade, cut two 25” pieces from a 72” long 1-½” piano hinge.

Center the hinges on the long edge of the side support wings and attach them with ⅝” screws.  To make mounting easier, lay the hinge over the edge and hold it tight against the corner while attaching the screws.  Make sure you are attaching it on the opposite side of the support riser.

Mount the side wing supports to the miter saw stand base 2-¾” down from the top with ⅝” screws.  The supports should be flush with the front of the base when fully open at 90 degrees.  Use pieces of wood clamped to the supports to help position it flush with the front of the base as seen in the picture.  Have a helper hold the wing while you secure it.

Alright, that’s enough for today.  Next post you’ll mount the saw and all the upgrades on the Mobile Miter Saw Station.  And you’ll be left with this bad boy!

Head over now to Part 2:

Mobile Miter Saw Station Part 2:  Side wings, fences, and upgrades

RIDGID provided me with tools and/or monetary compensation as a sponsor of this build.  All opinions are my own and are not filtered by the sponsor.