DIY Rolling Table Saw Workstation with Router Table Extension — Build Plans

DIY Rolling Table Saw Workstation with Router Table Extension — Build Plans

A mobile table saw workstation with an integrated router table wing is one of the smartest upgrades for a small or medium workshop. It combines two of the most important woodworking machines into one compact rolling unit while adding storage, support surfaces, and improved workflow.

This design includes:

  • Central table saw bay
  • Router table extension wing
  • Outfeed support surface
  • Heavy-duty rolling base
  • Storage compartments
  • Full workshop mobility

Two major machines. One footprint. Maximum efficiency. Access over 16,000 woodworking plans

Finished Dimensions

Overall Station Size

  • Width: 1400mm
  • Depth: 800mm
  • Height: 900mm

Router Wing Width

  • 450mm

Outfeed Surface

  • Flush with saw table height

Workstation Overview

This workstation combines:

  • Cutting
  • Routing
  • Material support
  • Tool storage
  • Mobility

Into a single integrated woodworking station.

Why This Design Works

Small workshops waste enormous space on separate machines.

This workstation:

  • Saves floor space
  • Increases workflow efficiency
  • Adds outfeed support
  • Keeps tools mobile
  • Improves material handling
  • Creates a centralized work area

Main Layout Breakdown

Section Width
Table saw bay 900mm
Router table wing 450mm
Side cabinet/frame Remaining structure

Base Frame Construction

Frame Material

Use:

  • 90 × 45mm structural timber

OR:

  • Double-layer plywood cabinet construction

Base Frame Size

  • 1300 × 700mm

Leg Assembly

Leg Size

  • 90 × 90mm laminated legs

Leg Height

  • 760mm

Add cross braces for rigidity.

Table Saw Bay

Opening Size

  • 650–750mm wide

Sized for:

  • Jobsite table saw
  • Contractor saw

Flush Table Alignment

The saw surface must align exactly with:

  • Router table wing
  • Outfeed surface

Use:

  • Shim blocks
  • Adjustable mounting rails
  • Leveling bolts

Router Table Extension Wing

Wing Size

  • 450 × 800mm

Router Plate Opening

Plate Opening Size

Typical:

  • 235 × 298mm

Sized for:

  • Aluminum router insert plate

Router Mounting

Router Position

Mounted beneath extension wing.

Recommended:

  • 2HP+ plunge router

Router Fence

Fence Size

  • 800mm long
  • 90mm tall

Include:

  • Dust port
  • Adjustable faces
  • T-track system

Outfeed Support Surface

Outfeed Depth

  • 300–500mm beyond blade

Supports:

  • Long boards
  • Sheet goods
  • Safer ripping

Lower Storage Cabinet

Suggested Storage Areas

  • Router bit drawers
  • Push stick storage
  • Blade storage
  • Jig storage
  • Fence accessories

Casters

Recommended Casters

  • 100–125mm locking casters

Weight Rating

Minimum:

  • 100kg per caster

Use through-bolts and reinforcement pads.

Dust Collection System

Table Saw Dust Port

  • 63–100mm port

Router Dust Port

  • 63mm fence port

Optional shared collection manifold.

Electrical Setup

Power System

Install:

  • Internal power strip
  • External master switch
  • Cord management hooks

Optional:

  • Emergency stop paddle

Recommended Materials

Best Top Material

  • Laminated plywood
  • Melamine plywood
  • MDF with laminate surface

Smooth surfaces improve feeding.

Fence Compatibility

Ensure rip fence clears:

  • Router wing
  • Outfeed area
  • Storage sections

Assembly Sequence

  1. Build lower frame
  2. Install legs and braces
  3. Create table saw bay
  4. Build router wing frame
  5. Install outfeed support
  6. Mount tabletop surfaces
  7. Install casters
  8. Align saw and router heights
  9. Install router lift or plate
  10. Build router fence
  11. Add storage compartments
  12. Install dust collection
  13. Finish and seal surfaces

Recommended Height

Final Work Height

  • 900mm typical

Adjust to match:

  • Existing workshop tools
  • Comfortable wrist height

Optional Upgrades

You can expand this station with:

  • Fold-down outfeed table
  • Built-in router lift
  • T-track clamping system
  • Drawer cabinets
  • Integrated vacuum switch
  • Fence storage rack
  • Sliding crosscut table
  • LED task lighting

Safety Features

Always include:

  • Blade guard
  • Riving knife
  • Push sticks
  • Router bit guard
  • Emergency stop switch
  • Dust extraction

Never operate without proper guarding.

Recommended Finish

Top Surfaces

Use:

  • Polyurethane
  • Laminate
  • Paste wax

Base Cabinet

Use:

  • Shop enamel paint
  • Satin polyurethane
  • Hard wax oil

Why Combo Workstations Are So Popular

A combined saw/router station provides:

  • Massive space savings
  • Better workflow
  • Shared outfeed support
  • Easier dust collection
  • Improved efficiency

It becomes the centerpiece machine station of the entire workshop.

Final Thoughts

This rolling workstation combines:

  • Precision ripping
  • Edge routing
  • Material support
  • Mobile storage
  • Compact efficiency

Into one powerful workshop build.

Two essential woodworking machines. One mobile workstation. No wasted space. Access over 16,000 woodworking plans 

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