Build an inexpensive stand for maximum comfort and efficiency
Standard scroll saw tables require you to stand or use a high stool or chair. I find both of these options uncomfortable after just one hour at work on the saw. To increase my productivity and allow me to work comfortably for extended periods of time, I designed a scroll saw stand to my own specifications.
The first stand was designed for my Dewalt DW788. I designed it to be the right height for me to work while sitting in a comfortable chair. I made a similar stand for my RBI Hawk G4 saw. The G4 has an enclosed base that is more difficult to attach to the stand. Both versions use readily available 2x4 studs and ¾"-thick plywood.
Step 1: Determine the optimum height. Sit in the chair you plan to use at the saw. Hold your arms at a comfortable sawing height–your arms, from elbows down, should be close to horizontal. Have someone else measure the distance from the floor to the bottom of your arms. For me, it was 33". Enter the measurement in Box A.
Step 2: Determine the length of the table legs. Measure the distance from the base of the scroll saw to the top of the saw table. Enter the measurement in Box B. Enter the thickness of the plywood to be used for the top of the stand in Box C. Add Box B and Box C together and record the measurement in Box D. Subtract Box D from Box A and record the measurement in Box E. My sample calculations are listed in the chart.
Step 3: Cut the legs to size. Cut the eight legs to the length recorded in Box E. Nail or screw together the four pairs of 2x4 legs to create four 4x4 legs.
Step 4: Determine the size of your table. It should be 24" wide. The length can vary from 28" to 32". Cut four 2x4s that are 3" less than the length of your table for the long stand supports. Cut four 24"-long pieces of 2x4 for the short stand supports.
Step 5: Attach the long table supports to the legs. Place two of the legs on the floor with the 3" width facing you. Position one long support across the legs on one end. Use a large square to ensure that the top of the long support is square to the legs. Nail or screw the long support to the legs. Use the same technique to attach a long support to the other two legs.
Step 6: Attach the long supports to the bottom of the legs. Make a mark 4" up from the bottom of both legs. Place the lower edge of the long support on the marks and attach the support to the legs with nails or screws.
Step 7: Attach the short supports to the legs. Match the ends of the short supports up with the ends of the long table supports. While the long supports end at the edge of the legs, the short supports extend to the outside edge of the long supports. Make sure the supports are square to the legs and nail or screw all four short supports in place. Work on one end first, then flip the stand to attach the other two supports.
Step 8: Fasten down the stand top. (If your saw has an enclosed base, proceed to step 9.) Cut the plywood to size, based on your stand. Nail or screw the plywood to the legs and supports. Place the saw on the table and use a pencil to mark the mounting hole positions on the plywood top. Drill holes through the plywood, then bolt the saw down using the largest bolts, nuts, and washers that will fit through the mounting holes in the saw base.
Step 9: Cut any required holes in the bench top. Some saws, such as the Hawk G4, require you to cut a hole in the top for the motor. Cut the plywood to size, then determine the location of the motor, and transfer the measurements to the plywood. Drill a ¼"-diameter bladeentry hole and use a saber saw or jigsaw to cut out the required area. Nail or screw the plywood top to the legs and supports.
Step 10: Make the mounts for an enclosed base saw. Position the scroll saw on the stand and trace around the perimeter of the saw with a pencil. Remove the saw and glue four 2x4 scraps inside the four corners you just marked. Place the scroll saw in position before the glue dries to ensure a perfect fit. After the glue dries, attach the scroll saw to the blocks with four 1"-long wood screws.
*To mount enclosed-base scroll saw to table top
See the image gallery for an exploded assembly drawing