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Step 1. Saw Dust Compartment with Door
Cut a board that fits snuggly between the top and second shelf. This will trap saw dust
Slide in the board.
Drill two pilot holes on the top shelf into the board, and two on the second shelf into the board
Countersink the pilot holes
Tighten with woods screws
Cut a board for the door. The side should be at 90 degrees, and the top and bottom should have a slight bevel. I cut to size and then sanded until the door opened and closed without too much of a gap
Add hinges on top
Add a knob to open the door, and a slider to keep the door closed
I also add a stop on the inside to the door didn't go back too far and put stress on the hinges
Step 2. Add Table Saw
My table saw has a rear shelf with support poles. The shelf isn't very stable. So, I removed the shelf and poles.
Drill a hole in the back above the top shelf for the power cord
Place the table saw on the top shelf. Mark the table saw's four holes, remove the table saw, and drill holes through the top shelf
Flip the table saw over and measure the hole for the saw dust to drop through. Transfer this hole to the top shelf. Drill a small starter hole, and then use a jig saw to cut the hole for the saw dust
Put the table saw on the top shelf. Pull the power cord through the hole. Attach the table saw to the top shelf with washers, bolts and locking nuts
Step 3. Wood Putty
The case is held together by screws, which should all be counter sunk. Also, there are imperfections ion the edges, and in the outside plywood.
Mix some putty using wood glue and saw dust
For the first pass, I used just glue and sawdust
For subsequent passes I mixed the glue with a little water so it flowed easily
I used a plaster's putty knife to fill in the holes and make it roughly even with the surface
Step 4. Sand
Sand everything until you like its feel
For example, I rounded over the edges just a little bit. From far over the corners look sharp, but close up they aren't sharp
After sanding, I inspected and added more filler as needed and then re-sanded until everything was smooth
I used an orbital sander with fine grit sand paper
Step 5. Paint
My garage shelves and tool cases are back.
So, I painted much of the case black using a semigloss paint and primer in one
I out on two coats and gently sanded between coats
All Done !
All Done !
swing out leg bolt
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