009 Panel Saw: A cost saving shop alternative

Panel Saw

Panel Saw

This Panel Saw project is a great alternative to the costly manufactured versions. Designed to be build using construction grade material for 95% of the components.

Of course you could forget the legs and use it as a vertical saw on a basic angled base to take up less space in the shop. You would likely want to reverse the feed position of the saw as there is no mechanical linkage to aid in feeding the saw. A plunge style saw like you use on a track saw would make this a very viable option.

The carrier is routed to fit your circular saw base in two directions. When making a rip cut you mount it in the direction of the cut and push your work through the stationary saw. The turn the circular saw 90 degrees to the fence for cross-cuts. You should attach a hold-down toggle clamp to secure the base of your saw to the carrier for added safety.

Panel Saw

When making rip cuts on the saw the carriage is locked down at the required distance from the fence. The material is the fed across the table while up being pushed against the fence. For cross cuts rotate your saw and cut away. There is plenty of room for 50” width material.

When designing this panel saw plan I used my own Dewalt DW369 circular saw as a template for the carrier. Obviously you will have to make one to fit your own saw. I’m also going to make a sub-base for my router that will fit in the saw cut-out so a router can be used in place of the circular saw. Enjoy your new workshop addition. Happy woodworking.

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008 Dead Blow Mallet

 Dead Blow Mallet

This dead blow mallet is a fun, useful project that I use on basically every project. Anything that I build for the shop is designed and built like it’s going to a customer. So the mallet was no exception.

Dead Blow Mallet

This little persuader was made with Maple and Paduk just to make it stand out in a crowd. The mallet is filled with lead pellets for weight. In my case I used BB’s to give it the weight required to function properly.

This style of hammer works because of the weight added to the hammer head. The head doesn’t bounce like a solid hammer. Therefore you get a solid strike every time.

The head on the mallet has a leather face added to protect whatever needs to be adjusted. If you do build this dead blow hammer I know you won’t be disappointed. It will come in very handy and be put to use on the majority of your projects.

I made one of these mallets years ago and have used it so often that I’ve had to replace the leather face pads twice now. I’m sure yours will get used all of the time as well. Plus of course it is a cool project!

So get to the shop and build your own. I don’t loan mine out 🙂

Happy Woodworking!

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