Making a Portable Workshop

Published : 03/08/2016 13:17:08
Categories : DIY Tools

A Portable Workshop for those of you that don't have much space or a compact cabinet you can carry all your stuff to work in other locations.
It has wheels so it can be moved by only one person and you can even carry it in your car with a little help to get it in, of course.
I tried to use common tools and cheapn and easy-to-find materials.

As you can see it has 3 functions. Saw table, Router and Scroll Saw. Also it has a big cabinet you can use to carry some of your tools with you.
It has a door lock, to to prevent theft and keep it safe if you have kids arround.
In order to achieve optimal results, quality tools are required. Cheap tools can do the job too, but the more you spend here, the better the results will be. You'll be able to keep using them in other works as you can easily remove and assemble them back again.

Dimensions Closed: 900mm high, 540mm width and 815mm depth.
Dimensions Open:   900mm high, 1400mm width and 815mm depth.
Total aprox weight: 55kg

These plans are for a router or drill with european neck (43mm), a circular saw Makita 5903r and a Jig Saw Festool PSB 300 EQ, to install other models you may have to modify a bit the plans. 

To show you how it works, I am going to build a pair of drawers with cheap pine floorboard.

Here I'm cutting the parts for the drawers with the Table Sled.

Now I used the Fence to get the desired height.

This is the groove for the base.

You can make angle cuts with the Miter Gauge.

Removing the quick access covers you can tilt the disk. 45 degrees in this case.

The Jig Saw Guide is adjustable in 3 axis and we can use different blade sizes. From one hundred to one hundred and eighty millimeters , getting a maximum cutting height of seventy milimeters.

Here I am making the drawer handle.

Let's go with the milling function.

I am changing the mill in order to get rounded corners.

We also have a miter channel here to use the Miter Gauge.

This bearing will be so useful to make curved millings.

We can also tilt the router 45º.

The drawer is finished so I am gonna put it in place.

Now I want to show you 2 different ways of making Tenons. First with the Jig Saw, the Fence and the Miter Gauge.

And the second one with the disk and the Tenon Jig.

With the bigger disk I can place in my circular saw (235mm) I get a max cutting height of 70mm.

The incra miter chanel has little adjustment bolts to reduce tilt. You can even block it if you need to.

This is my solution to make the Box Joints.

You must place half of the pieces in the one side and the other two in the other side.

And this is the final result.

Back to the router again, this time with the Featherboards, to make the groove of the base.

To close it, we must lift up the Circular Saw and tilt the router 45º.

Let's start cutting the parts following the cutting list and mark them all with their numbers.

Here I'm making 4 drill holes for the handle and cutting it with the Jig Saw.

Make a drill with the same depth as the thickness of the washer for the opening system.

Countersink the drill holes.

Here is where the power and emergency switches go.

Now you can start assembling the cabinet using 50mm screws and dowels.

It is not necessary but you can apply a coat of lacquer if you want for a better finish and durability.

Here I'm cutting the 3 top parts.

Then cut and drill the frames for the hinged covers.

Make the holes for the steel pipe so it fits slightly loose, as it is the axis of rotation of the hinged covers.

I made the milling for the circular saw in the 3d router, If you don't have a similar tool, you can do it with the manual router using guides or templates.

Here I am making a milling on the top for the quick access covers, wich will make easier changing the disk. You can use the cover itself to calibrate the depth of the milling.

Try the Circular Saw to the top of the table and mark holes.

The 3D Router comes in very handy here, as the column drill won't work because of its reduced work space.

Ok. Let's continue with the second part of our home made Portable Workshop.

Mark the place for the miter channel following the plans and make a groove cut in the Circular Saw

These two pieces of plywood will give us a deep thickness to screw the Miter Channel.

Here I am making a rabbet with the depth of the Self Adhesive Measuring Tape. You can find a link in the description if you want to know where you can buy it.

Then screw it to the cover.

This is the hole for the Router

Cut the pipe and assembly the frames for the hinged covers.

Prepare the stoppers and assembly them according to the plans.

Put the cover of the router in place and screw it to the frame using the holes of the miter channel.

Mill the cover and make this inner rabbet to place the Jig Saw.

If you are not using a sliding surface as melamine, you should apply a coat of lacquer and sand it before and after.

Cut and mechanize the parts for the vertical Router Holder.

This is the mill for the height adjustment of the Vertical Router.

Glue two plywood parts to build the spindle mount.

You should use a drill of the exact diameter or an adjustable one like this when building the router holder.

Also you can make it on a CNC or even buy it online.

Assemble the spindle mount in the holder.

And now we can try the lift system.

Assemble the hinges provisionally to mark the turning radius.

I'm using these plywood remnants for making the wooden knobs.

I will start with this parts I forgot to assemble in the last video. They will give more stability to the lift system.

Here I'm cutting the parts for the base in my Homemade Saw Table.

Assemble and screw to the bottom of the cabinet. It should have the same size as the wheels you've chosen.

I've placed a barrel bolt in one of the hinged covers and a door lock in the other. They can be useful when transporting the workshop and to prevent theft.

Prepare the electrical installation consisting of a power strip with four sockets. Where we will connect the router and the jig saw. The other 2 sockets will be useful for connecting other portable tools.

The socket for the Circular Saw has an on/off switch and an emergency stop button.

This is the internal winding wire system.

I made this quick access covers with opal methacrylate.

Place and try the Circular Saw.

With a metal bracket I have adapted this bearing that I bought with an old router. It can be so useful for curve millings.

Finally we check the hinged covers are aligned with the top of the table. If not, it' s easy to correct the tilt adjusting the stoppers.

Insert a steel pipe in the router to check the squareness in all directions.

Also check the squarness of the disk and make sure it is parallel to the Miter Channel.

Do the same with the Jig Saw and finally.

Finally close it and check out the tools are not touching each other inside.

In this video I am making some of the accessories for the Portable Workshop.

Let's start cutting the parts of the Sled.

This is a channel to center the Miter Slider.

Screw two pieces of plywood taking care of the positions of the screws because we are going to cut it later and it could be dangerous.

Groove the place for the Measuring Tape.

Apply lacquer before and after sanding to get a sliding surface.

Assemble the sled, put it on the miter channel and cut the remaining part.

Turn it and make a cut in the middle like this.

Stick the measuring tape in place.

Disassemble the holder of the Sled and make a channel for the Box Joint Jig. The same one of my other Table Saw.

Adjust the slider channel until no tilt remains with this two bolts. You can even block it if you want tightening the screw at its maximum.

Cut the pieces for the fence. Assemble, lacquer and sand it.

This is the tightening system for the Fence.

Glue a couple of dowels that we will use as a guide.

Assemble the knob and try the Fence.

This is the Router dust collector.

Put the threaded inserts for the featherboard.

Check the disk is parallel to the fence and stick its measuring tape in the groove.

Prepare these pieces to make template of the Box Joint Jig.

Finally apply the glue and sand it.

This is the last video of this How I did it tutorial.

Here I am building the Miter Gauge.

You can glue the Printable Templates of the plans in the plywood or use a ruler.

You can already cut it in the machine.

The Incra miter slider threads are in inches if you rather use the metric system you can use a tap as I am doing here.

Try it to make sure the turning radius is the correct one.

Cut the parts for the Tenon Jig.

You expand the thickness if you need reduce the friction.

Glue the Printable Templates to the plywood to make the featherboards.

Make the adjustment slots in the Router.

Screw the threaded inserts.

Let's start making the guide for the Jig Saw. The tightening system is the same as the one used in the Fence.

Assemble the system for the adjustment of the bearings.

Use a metal plate to preventing the blade from wearing out the plywood.

With the drill make one of the holes bigger to allow the adjustment of the bearing.

Do the same with the plywood part.

Mechanize the height adjustment system .

Now we can move it on three axis to place it in the exact position we need.

Now I am gonna check if it works making my new push stick.

It is important to hold the piece you are cutting with two hands to keep it in place.

Where to get some materials and tools used in this project:

Visit the Portable Workshop Topic in Forum:

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View all comments (55)

LewJoe57


01/13/2017 17:38:33

Very well done! Excellent workmanship! Will be PERFECT for my tiny home shop. Quick question, if you please, to your knowledge, has anyone converted your design for use with Imperial units (inches)? I live in the USA and access to metic-based lumber is difficult to say the least! I can do the conversions myself, but why repeat the work which may already be completed? Thank you!

Emilio


12/07/2016 06:05:37

Que tipo de material se usa para el cover de el circular saw?

Paoson Woodworking


08/13/2016 16:35:02

hola Waldo, si la caladora es de calidad no le pasa nada, yo llevo años usándola de este modo!

Waldo


08/12/2016 21:12:26

Te consulto: colocar la caladora en posicion invertida, no le provoca ningun inconveniente al motor, no trrabaja forzado?

Paoson Woodworking


07/15/2016 12:22:20

hola Rodolfo, mira en mi for, en la sección where to finf T Track profile, sale una web alemana ( http://www.feinewerkzeuge.de/t-track.html) que tienen todo y los gastos de envío son más o menos iguales que si comprases aquí!

Rodolfo


07/13/2016 20:11:36

Hola Paoson, gracias por el blog!Estoy haciendo el listad de todo lo que tengo que comprar y me surge una duda. Por un lado no se donde comprar el miter channel en España (he mirado en Pazos pero solo tienen el canal y no el slider), y por otro, ¿que diferencia hay con un tee-track?Un saludo y ánimo con el proyecto!

Paoson


06/15/2016 09:53:14

Gracias Alfredo,los planos incluyen un cutting list que puedes usar para conseguir las partes de madera ya cortadas y así transportarlas fácilmente. Utilizo contrachapado de 9 y 18mm

Alfredo Sanchez


06/14/2016 23:59:55

Excelente trabajo mi estimado, soy de Mexico y me gustaría saber cual es el grosor de la madera, 1 pulgada? quiero comprar los planos solo que muchas veces es complicado transportar hojas o plieges de 1.22 x2.44 en mi auto :( aqui en Mexico venden hojas de 1.22X0.6 metrosMil gracias y sigue con el buen trabajo, soy fan de tu blog.

Paoson


06/13/2016 10:05:39

Thanks Dan,you can download all my plans here:http://paoson.com/downloads/

Dan Sherman


06/11/2016 14:40:54

Your portable workshop is great. I would like to get/purchase SketchUp plans for your box joint jig if they are available. I'm about to try and make it by estimating what I see in the video, but I'd be more than happy to pay for actual plans if they were available.Thank you.

Paoson


05/09/2016 12:12:27

Hi Fergal,take a look at this:http://paoson.com/downloads/en/forum/114s

Fergal


05/08/2016 13:16:20

Hi, I would like to know what brand of Router you have used on your Portable Workshop and a model, so I can match it the best I can as I am in Australia and it is very difficult to find a Router with a 43mm collar, I have only been able to find Routers with a 63.5mm collar without having to order a unit online to get one with a 43mm collar. Thanks

AlexWeb


05/03/2016 14:07:09

I just bought your plans, can't wait to start building the workshop :)

Eli


04/25/2016 20:57:51

Hi I am from Israel I would like to know how can i get the blueprint for this workstation to try and build it for my self

Paoson Woodworking


04/04/2016 10:24:22

Hola Martín, si, incluye todos los accesorios que salen en el vídeo. Gracias

martin


04/03/2016 07:06:07

en la compra de los planos de la estacion de trabajo,tambien se incluyen los planos de los accesorios?

Paoson Woodworking


04/01/2016 12:18:48

Hola Diego, lo siento pero solo vendemos los planos...puedes comprarlos y llevárselos a alguna carpintería donde seguramente te la pueden fabricar...muchas gracias!

Diego


04/01/2016 10:15:41

Hola paoson, quiero saber si haces estos bancos de trabajo,estos portable workshop, para vender,me vendría muy bien y no tengo tiempo para hacerme 1,gracias

buy patio online


03/30/2016 13:04:35

I like what you guys are usuallyy up too. Such clever work aand exposure! Keep up the good works guys I've added you guys to my blogroll.

Paoson Woodworking


03/21/2016 11:34:06

thank you so much "Handle Pintu" and "help wanted"

help wanted


03/19/2016 23:29:11

You caan certainly see your enthusiasm in the work you write. The arena hopes forr even more passionate writers such aas you who aren't afraid to mention how they believe. At all times goo after your heart.

Handle Pintu Jakarta


03/17/2016 11:40:52

These are in fact wonderful ideas in on the topic of blogging. You have touched some good factors here. Any way keep up wrinting.

Paoson


03/11/2016 17:06:39

Hi,42Mb

Adiet


03/11/2016 12:16:47

Hi, How big file size of zip downloaded portable workshop plan?

Paoson Woodworking


03/10/2016 19:33:42

Hola Luis, en el enlace "producto ligado" que se encuentra un poco más arriba en esta página encontrarás las medidas totales de la máquina y más información

luis


03/10/2016 19:26:24

hola quisiera saber las medidas e todo gracias

Paoson


03/02/2016 10:41:42

Thanks Ariel Nguyen, Jhonny and Martin! I only sell the plans, you can buy them by clicking in the shop link in the top of the page or copy and paste this link: http://paoson.com/downloads

Paoson


03/02/2016 10:36:42

It is not completely necessary but it can be useful for milling with the Miter Gauge.Take a look at minute 4:23 of this video:https://www.youtube.com/watch?v=2ZlFU7DjYZQ

Ariel Nguyen


03/02/2016 08:15:06

Hello Paoson, I'm from Hanoi, Vietnam and interested in your portable workshop. Do you sell this product? If yes how do you ship it to Vietnam ? Thanks and wait for your answer.

Jhonny


03/01/2016 21:53:49

Nice job Sir. When are be available the blueprints. Thanks.

Martin


03/01/2016 21:38:18

Great job mate.. Just purchased and about to get it done. Hope you will come up with something as excelent as this in the future. I will be in the row to buy another plans of you. BTW it looks like we share same combination of passions - wood and guitar:). Take careMartin from Slovakia

Martin


03/01/2016 21:36:28

Great job mate.. Just purchased and about to get it done. Hope you will come up with something as excelent as this in the future. I will be in the row to buy another plans of you. BTW it looks like we share same combination of passions - wood and guitar:). Take careMartin from Slovakia

Suso from Paoson


03/01/2016 20:08:33

<p>It is not completely necessary but it can be useful for milling with the Miter Gauge. Take a look at minute 4:23 of this video:&nbsp;<a href="https://www.youtube.com/watch?v=2ZlFU7DjYZQ">https://www.youtube.com/watch?v=2ZlFU7DjYZQ</a></p>

Feri


03/01/2016 18:03:46

Hello again,I have a questin about theis workshop. What is the function of the channel at the right side of the router?If I understand right the miter slider need just 1 channel for the circular saw but I don't know why we have the 2nd channel in the right side...I'm sure there is a functionality there so if you still have motivation to create additional video to present it, I'm sure lot's of people will thank it to you ;)Br, Feri

Paoson


03/01/2016 10:22:20

I don't sleep at night ;) Thanks bricabracwizard!

bricabracwizard


03/01/2016 05:06:28

How do you come up with these ideas Paoson? Absolutely brilliant! I'm still blown away with the 3D router and having fun using it! I bought but haven't started the router table plans. Keep it up!

nerobond


02/20/2016 12:06:46

I wanted to ask if you can also download the projects of various accessories for the working table , another question if I run the project plywood plywood can fit ? apologizes for the translation from English but I do with the translator of google , thanks again P.S. why do not you put the Italian in your projects ?

Paoson


02/19/2016 16:01:55

Hi everyone,the plans are already available for download!Thanks for your patience

Paoson Woodwork


02/18/2016 18:22:49

Hi nerobond,I hope they will be ready tomorow! Thanks for comment

nerobond


02/18/2016 17:37:19

when you can purchase the complete design of this bench ? I would be interested in purchasing thanks

Karwan shkur


02/17/2016 09:46:23

very nice job we waiting for the plan thanks

Paoson


02/15/2016 19:35:41

Thanks a lot Feri! ;)This one have more functions, but as a pure saw table, specially for big pieces I'd chose my old saw table. For a high workload and If you need a good dust collector, your choice would be the other.

Feri


02/15/2016 19:16:11

Do you think does this machine able to replace your first table what you shared with us? (Lot's of place in Hungarian forums call it 'the perfect tool for woodworker') The 'able to replace' means: -functionality for daily/frequent work -dust collection -precision point of view.Br, Feri

Paoson


02/15/2016 11:24:11

Hi Brian,length x width x height 530x810x900mmWhen open: 1410x810x900mm

Paoson


02/15/2016 11:16:04

Thanks Feri. Yes it is so stable even in the wings. In the next video you will see.

Brian Harvey


02/14/2016 11:04:40

Great idea and excellent video as usual. Can you please tell me the dimensions of the table, both open and folded, thanks.

Feri


02/13/2016 07:56:09

Great job!! I'm also waiting to the plans ;)Question: I believe the table is stable in the center where you builded the circular saw. But how stable on the left&right side where you builded the router? You can turn them and can fix with only small pieces of wood without any screw. Are they stable during you work on them?

Paoson


02/10/2016 13:59:09

Thanks all of you for comment,I hope the plans will be ready this week.

zouhair


02/10/2016 13:37:31

dear sir how are youplease im looking for this plan can you provide me thé price pleasethanks

Jan


02/08/2016 08:25:52

Hi Love your work :) When is the portable workshop going to be available in your shop?Regards Jan

Ben


02/08/2016 04:29:34

Your designs are ingenious! Why the designs for this one is not available? It is quite handy for someone who has a small workshop and moves around a lot!

Paoson Woodwork


02/05/2016 11:01:06

Hi Gunther,I hope they will be ready the next week.thanks for comment

Sergey


02/05/2016 10:59:14

Great job! Tell me, please, and whether the plans are available of this device? If yes, when?

FruehStuC


02/04/2016 09:45:47

I'd be pleased to buy the plans for this build. I'm looking forward to them becoming available.Nice Job!

Günther


02/01/2016 20:17:01

Hello my name is Gunther I am from Austria. Please excuse my english, it is the translator of Google. Want to ask you if you can send the blueprint of the circular saw, milling and jig saw me. mfG Günther

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