Table Saw: Case

I wanted to raise the table saw from an uncomfortable 35" height to 40". The height of the legs and and the casters (9"0 is subtracted from the desired height (40") to get the case height (31").

The case supports the table saw and is built out of 1-1/8" plywood

Start

Part 2

Step 1. Cut the plywood to size

The dados and rabbits are an important part of the shelves' measurements. And are key to cutting the board to the correct size
- 1/2" dados and rabbits are cut in the sides and the back
Cut 2 sides 20-1/2" x 31"
Cut back 34-1/2" x 31"
Cut 2 shelves and 1 bottom 33-1/2" x 20"
- 1/2" dados and rabbits on each side (34-1/2" - 1/2" - 1/2" = 33-1/2")
- 1/2" dados and rabbit on back (20-1/2" - 1/2" = 20"

Step 2. Cut the rabbits

Insert a dado blade in table saw.
- The width of the dado blade should be the same as the width of the plywood
Remove the safety blade cover from the table saw
Set the dado blade to be 1/2" above the table saw
If necessary, add a sacrificial fence to the table saw's fence, which is a piece of wood held in place by clamps. The wood allows the saw blade to turn without catching on the sacrificial fence.
Cut rabbits on the inside edges of both sides and the bottom of the back
Cut a rabbit on the inside bottom of both sides

Step 3. Cut the dados

The shelves slide into the dados
Measure the height of the table saw (11-3/8")
The top dado should be 11-3/8 from the top of the back and the two sides
Set a stop on the table saw so the two sides and the back dado are cut at same height
The middle dado can be wherever you would like. I set mine at 9" below the bottom of the top shelf's dado (20-3/8")

Step 4. Do a dry fit

I forgot to do this, and somehow one side's dado was off by 1/8"
It is much easier to fix things before glue has been applied

Step 5. Drill pilot holes

Drill pilot holes from the inside and in the middle of the dados and rabbits
I put pilots hole at the front of each shelf and the bottom. I also put pilot holes at the top and bottom of the back's rabbits.
Them I spaced the other pilot holes equally
Once all the pilot holes are drilled from the inside, I flipped the boards over and drilled countersinks in each pilot hole

Step 6. Reassemble, glue and screw

Apply glue to the dados and rabbits
Reassemble the case
Extend the pilot holes into the shelves and bottom to prevent splitting
Add the screws into each pilot hole
The screws hole the case together while the glue dries
Everything should be square, but double check
If required add clamps
Let the glue dry overnight

Go to Part 5 or revisit a previous page.