Andy Gullion, a contractor in Huntsville, Alabama sent these photos of a work stand he built for his miter saw. The stand has an interesting pedigree; it replaces the Paulk Miter Stand that originally stored in a dedicated space in his tool trailer. But after adding a fence, the stand no longer fit so he relegated it to the shop and built the smaller one shown in this story. The new stand incorporates some of the features/principles of the original but is lighter and easier to haul onto the jobsite.
Like Paulk’s stand, it has two tiers, the upper for the material being cut and the lower a shelf where tools and supplies can be kept nearby but out of the way. But Gullion’s stand is more simply constructed; instead of being a torsion box with openings cut through the sides it’s a split ½-inch plywood top supported over a ½-inch plywood shelf by ¾-inch plywood spacers. He could have used ¾-inch plywood for all but that would have been heavier.
When Gullion told me about his stand he made a point of crediting Ron Paulk for unselfishly sharing his designs and the function and work flow they were created to support.
The stand is a top and extensions that rest on foldable sawhorses and stock supports. The basic unit is 8 feet long but expands to 16 or 24 feet, making it perfect for cutting long runs of MDF crown. Note the stiffener along the lower front edge of the shelf; the back edge is stiffened too. Those holes through the stiffener (“dog holes”) are for clamping.
The top is about 14 inches deep and provides full support when cross-cutting the wide material used for closets and built-ins. The top is equipped with a Kreg Precision Trak and stop system and dog holes for clamping.
The extension wings key into oversize dovetail. The stand is 8 feet long by itself and 24 feet long with both extensions in place.
The dovetail “joint” is held together by a bolt attached to a knob. The bolt passes through a gusset on the underside of the top and screws into a threaded insert in the male side of the dovetail. The extensions go on quickly and attach solidly.
Gullion’s miter saw is bolted to a plywood sub-base. To insure the saw always installs in the same position—with its fence parallel to those of the stand—the sub-base is dadoed to fit over a “key” on the back edge of the bench.
The sub-base is sandwiched between plywood blocks—to insure the saw always installs in the same position left-to-right on the stand. This lessens the need to calibrate the length stop system because it too is keyed to the top. In this photo, the fence and length stop are not attached to the stand. The fence keys over the small piece of wood projecting up from the right rear edge of the stand. Note the clever use of sash locks to hold the sub-base in place, a feature that was touched on in Andy’s Amazing Tool Trailer. The knobs used to attach the extensions store on the spacer to the right of the saw (the two closest to the front edge).
Here’s a view from the back side of the stand as the fence and stop system are about to be attached. Look closely and you’ll see the “mortise” used to key the fence to the block on the back of the stand.
Same view as in previous photo but with the fence and stop system all the way down.
This is a view into the back of Gullion’s tool trailer. The top and extensions for the miter saw stand store in a dedicated space below the trailer’s work bench. The sawhorses and stock supports store elsewhere in the trailer.
The stiffeners on the front and back edges of the stand’s lower shelf act as spacers, allowing track saw guide rails to store in the same space. The rails can be pulled out without disturbing the stand—and vice-versa. One of the organizational principles of the trailer is that nothing in the trailer should have to be moved to gain access to another.