Q01Prototype
What is the final caster model and capacity?
Confirm plate geometry, foot travel, and capacity at the most heavily loaded caster line.
Blocks: Plinth batch cutting
Shop project 02 · Revision C
Miter saw + radial arm saw station
A complete, measured build sequence for two mobile 96-inch modules. The RAS faces the operator aisle with its table flush to the worktops; the tall connector cabinet closes behind a door and holds a removable vertical blade pullout.
- Overall
- 192 × 30 × 36 in.
- Modules
- 2 × 96 in.
- Left module
- 30 / 36 / 30 in.
- Right module
- 12 / 36 / 48 in.
- Carcass depth
- 24 in. nominal
- Finished plane
- 36 in.
Readiness gate
The design is not released for final cutting.
2 of 13 questions resolved. Prototype and field-fit answers control the dependent cuts; a checked box without a written answer does not count.
2/13decisions closed
Architecture
The full station at a glance
The 96-inch seam falls between the left storage module and the 12-inch connector cabinet. That narrow cabinet stays with the right module and carries the locating and clamping hardware.
30 storage
36 storage
30 storage
12 door + blades
36 Bosch
48 front-facing RAS
Left module · 96 in.Right module · 96 in.
Phase 1 · Prototype
One caster station, built full size
A single FOOT MASTER GDH-75-ASF-NYD-FBL bolted through a full-thickness LSL pad, with a scrap plywood panel standing in for the cabinet bottom. It proves the pad thickness, bolt pattern, access-hole diameter, swivel clearance, and the real support-plane height before any plinth material is cut.
The pad is laminated to 3 in. total thickness so the through-bolts and 1-1/4 in. access hole have enough material to stay true under load. Two layers of 2×4 or 2×6 LSL scraps are enough; cross the strand directions when gluing so the pad resists splitting and creep.
Parts and dimensions
- Pad, two LSL layers6 × 6 in. × 2 × 1-1/2 in. (3 in. total)
- 2×4 or 2×6 LSL scraps work fine. Glue and screw the laminations; cross strand directions between layers if possible.
- Caster plate footprint90 × 90 mm (3-1/2 in.)
- Centered on the pad; leaves ~1-1/4 in. of pad outside the plate on all sides.
- Through-bolt pattern70 × 70 mm square, 9.5 mm holes
- M8 or 3/8 in. hex bolts, 4-1/2 in. long, flat washer + lock washer + nut on top.
- Leveling-shaft access hole1-1/4 in. dia., pad center
- Drill from the top with a Forstner bit; enlarge only if the socket binds.
- Simulated cabinet bottom12 × 12 in. of 3/4 in. plywood
- Screwed to the pad so the socket reach matches the real cabinet interior.
- Test load300–500 lb of sheet goods or weights
- Stack over the pad center; leave loaded for 24 hours before re-measuring.
| Measurement to record | Target / acceptance |
|---|---|
| Rolling height (feet retracted) | ≈110 mm / 4-5/16 in. plate bottom to floor |
| Deployed height (foot down, wheel free) | Up to 145 mm / 5-11/16 in. — record the actual working setting |
| Wheel unload | Wheel spins freely by hand with the pad fully loaded |
| Swivel sweep clearance | 64 mm offset — no contact through a full 360° rotation |
| Socket access | Straight, un-cocked engagement on the M16 nut through the hole |
| Pad integrity after 24 h load | No crushing under washers, no pull-through, no splitting, no creep |
Controlled dimensions
Know what is fixed—and what is not
| Item | Value | Release status |
|---|---|---|
| Finished worktop | 192 × 30 × 36 in. | Controlled |
| Each movable module | 96 in. long | Controlled |
| Top stack | 3/4 in. plywood + 1/2 in. MDF + laminate | Controlled |
| Top of carcass | 34-3/4 in. target | Measure |
| Bosch platform | Jack-screw adjusters, height field-fit from inside the cabinet | Field-fit |
| RAS table | Flush at 36 in.; saw faces front | Field-fit |
| LSL plinth crossmembers | 21 in. | Controlled |
| Caster pads and access holes | Size from actual hardware | Prototype |
Before completing the design
Questions to answer before cutting
Record the measured or selected value, then mark it resolved. Each card names the work that must wait.
Saved on this device
Q02Prototype
What are the mounting-plate and through-bolt dimensions?
They determine pad size, edge distance, blocking, and fastener length.
Blocks: Caster pads
Q03Measure
What is the loaded plinth support-plane height?
Carcass height must be calculated from the real prototype, not a catalog drawing.
Blocks: Carcass side panels
Q04Prototype
Which socket and access-hole diameter provide straight adjustment?
All twelve leveling feet must remain accessible from inside the cabinets.
Blocks: Access holes
Q05Measure
What is each module’s estimated fully loaded weight?
Caster selection and safe relocation depend on realistic machine, cabinet, top, and storage loads.
Blocks: Caster approval
Q06Field-fit
What are the blade pullout’s clear inside dimensions?
The door, slides, pegs, tooth spacing, dado storage, and connector access must coexist in 12 inches.
Blocks: Door and blade pullout
Q07Field-fit
What is the Bosch platform footprint and full movement envelope?
The shelf and adjusters cannot interfere with bevel, glide, battery, controls, or dust hose.
Blocks: Bosch bay
Q08Field-fit
What deck height and clearances does the front-facing RAS require?
Measure crank sweep, column, carriage, blade, guard, fence, and rear hose on the actual saw.
Blocks: RAS bay
Q09Measure
Is the RAS guard and recall status confirmed?
Do not energize the saw until the official remedy and full blade guard requirements are satisfied.
Blocks: RAS operation
Q10Design
Which laminate goes on each module?
Assign the available sheets before cutting and bonding the top skins.
Blocks: Worktops
Q11Design
How will dust collection and electrical service be routed?
Hoses and cords need service loops without crossing controls, pullouts, or blade travel.
Blocks: Storage fronts
Q12Field-fit
Where do the three 48-inch Combo Tracks land after calibration?
Track recesses are routed only after both machines and the full 16-foot plane are stable.
Blocks: Track routing
Q13Measure
Can each 96-inch module pass through the relocation route safely?
Verify doorway width, turns, handling weight, and which tops or boxes must detach.
Blocks: Final assembly strategy
Construction sequence
Twelve phases, in dependency order
0/57 build tasks- 010/5
Prototype one caster station
Prerequisite
Actual caster, socket, bolts, and representative LSL/cabinet material in hand.
- Confirm the delivered FOOT MASTER GDH-75-ASF-NYD-FBL caster matches HVH order 26-16066C.
- Laminate a full-size mounting pad and through-bolt the caster.
- Verify 360° swivel, wheel clearance, foot travel, and straight socket access.
- Load the sample; inspect for crushing, pull-through, splitting, sliding, and creep.
- Record the loaded support-plane height.
Stop condition
Do not duplicate pads or drill all twelve access holes until the prototype passes.
Acceptance
Wheel unloads completely; foot is stable; adjustment remains accessible.
Prototype caster station · one laminated pad, one caster, socket access proven before repeating it twelve times - 020/5
Build both LSL plinths
Prerequisite
Phase 1 dimensions recorded and caster capacity approved.
Materials for this trip
2×6 LSL2 × 20 ft2×4 or 2×6 LSL15 × 21 in.Four 96 in. rails; leaves ~8 ft margin for miscuts. Crossmembers. Use existing 2×4 scraps to avoid buying a third 20 ft 2×6.
- Cut four 96-inch long rails from 2×6 LSL on edge. 2×4 LSL is acceptable only if laminated face-to-face into a 3 × 3-1/2 in. beam, or capped with a flat 2×4 to form an L-girder.
- Cut fifteen 21-inch crossmembers from 2×4 or 2×6 LSL.
- Build the left plinth rails at 0, 6, 30, 48, 66, 90, and 96 inches.
- Build the right plinth rails at 0, 6, 12, 42, 48, 72, 90, and 96 inches.
- Install twelve laminated 3-inch pads and casters at the tested support lines.
Stop condition
Reject any twisted assembly or fastener with inadequate edge distance.
Acceptance
Both plinths are square, flat, rigid, and roll freely with feet retracted.
Plinth build · four 96-inch rails, fifteen crossmembers, twelve casters on laminated pads - 030/4
Establish carcass height
Prerequisite
Both loaded plinths can be positioned on the actual garage floor.
- Level each plinth on deployed feet without forcing twist.
- Measure floor-to-carcass support plane at multiple points.
- Include actual plywood, MDF, laminate, and adhesive thicknesses.
- Calculate cabinet side height to place the finished plane at 36 inches.
Stop condition
Do not batch-cut cabinet sides from nominal caster dimensions.
Acceptance
A written side-panel height produces the 34-3/4-inch carcass target.
Height take-off · measure the loaded support plane, then back-calculate the cabinet side height - 040/4
Build the cabinet carcasses
Prerequisite
Carcass height and service-hole positions are released.
- Build three independent left boxes: 30, 36, and 30 inches wide.
- Build the full-height 12-inch connector cabinet, 36-inch Bosch bay, and 48-inch RAS bay.
- Use 3/4-inch prefinished birch; add backs, gussets, or deep stretchers where required.
- Anchor loads into LSL or blocking—not plywood edges—and preserve caster access.
Stop condition
Do not let partitions cover top-adjustment holes or connector hardware.
Acceptance
Boxes are square, independently rigid, and fit their marked plinth positions.
Carcass build · independent boxes, square and rigid, each sized to its marked plinth position - 050/8
Install the module connection
Prerequisite
Both 96-inch modules are level, their joining faces are square, and the 12-inch connector cabinet is open.
- Build the connection inside the 12-inch connector cabinet so it is hidden behind the closed door.
- Reinforce the joining faces with solid blocking where they meet inside the cabinet.
- Install T-nuts flush into the left module's joining face, oriented for the right module's knobs.
- Install one upper and one lower locating pin between the module faces.
- Drill matching clearance holes through the right module's joining face for the threaded knobs.
- Thread the knobs from inside the right module cabinet into the T-nuts on the left module; keep knob heads clear of the blade pullout.
- Check that the vertical blade pullout can slide past or be removed without touching the fasteners.
- Separate and reconnect repeatedly while checking alignment.
Stop condition
Do not let T-nuts, knob heads, or pins project into the blade pullout's travel or storage volume.
Acceptance
The seam closes repeatably without forcing, racking, or loss of elevation, and all fasteners stay hidden behind the closed door.
Module connection detail · T-nuts in the left module face accept threaded knobs from inside the right module cabinet, hidden behind the closed door - 060/4
Fit the door and blade pullout
Prerequisite
Connector fasteners and caster access locations are fixed.
- Hang a full-height door on the 12-inch connector cabinet.
- Build a removable vertical plywood pullout on full-extension slides.
- Space pegs so carbide teeth never touch; add compact dado chip, shim, and flange storage.
- Test door swing, pullout travel, latch, module bolts, and caster adjustment access.
Stop condition
The pullout must not carry structural joining load or open into either machine.
Acceptance
Door closes securely; pullout removes for service and protects every blade.
Door and blade pullout · spaced pegs keep carbide teeth clear, and the pullout lifts out for service - 070/6
Build the Bosch platform
Prerequisite
Actual saw footprint and full glide/bevel envelope are measured.
- Install a fixed lower shelf or solid block inside the Bosch bay to act as the support plane.
- Cut a separate 3/4-inch plywood platform sized to the saw base plus clearance.
- Drill the platform corners for 3/8-inch-16 jack screws with steel bearing plates underneath; add separate 5/16-inch-18 hold-down bolts with washers to clamp the platform without relying on the jack screws.
- Fit UHMW anti-sway guides against the cabinet sides so the platform cannot shift laterally under thrust or vibration.
- Rough-set the platform near 32-1/4 inches, then fine-adjust each corner from inside the cabinet below — this avoids reaching between the cabinet top and the platform.
- Mount the saw with manufacturer-approved hardware and verify every control position.
Stop condition
Do not close the bay until battery, bevel, glide, guard, and hose access are proven, and the platform cannot shift under thrust or vibration.
Acceptance
Saw table adjusts flush in both axes from inside the cabinet below, locks without movement, and the jack-screw + hold-down + anti-sway hardware keeps the platform square and laterally supported.
Bosch platform detail · jack screws and hold-downs adjusted from inside the cabinet, where there is full forearm clearance - 080/5
Field-fit the radial arm saw
Prerequisite
Guard/recall status resolved and actual machine geometry recorded.
- Orient the saw toward the cabinet front and operator aisle.
- Build a reinforced support deck tied into cabinet sides and the plinth.
- Provide the replaceable table and fence geometry required by the manufacturer.
- Shim or adjust until the RAS table is exactly flush with both adjacent surfaces.
- Sweep crank, carriage, blade, column, guard, and hose through full travel.
Stop condition
Do not energize the saw with unresolved guard status or any collision.
Acceptance
Front-facing saw is secure, guarded, operable, and flush at 36 inches.
Radial arm saw field-fit · saw faces the front, table shimmed exactly flush at 36 inches - 090/4
Build and laminate worktops
Prerequisite
Both machine elevations and all required cutouts are field-verified.
- Build the 3/4-inch plywood and 1/2-inch MDF structural stack.
- Apply assigned Wilsonart laminate and finish cherry edging near 1-1/4 inches.
- Field-fit right-side surfaces around the connector, Bosch, and RAS areas.
- Keep tops removable where needed for relocation and service.
Stop condition
Do not assume the right module is one uninterrupted rectangular top.
Acceptance
Surfaces are flat, stable, cleanly edged, and ready for calibration.
Worktops · plywood and MDF core, Wilsonart laminate face, cherry edge near 1-1/4 inches - 100/4
Connect, level, and calibrate
Prerequisite
Both complete modules are in their final operating position.
- Retract feet, position modules, engage pins, and install bolts finger-tight.
- Lower three widely spaced feet per module to establish planes; bring the rest into shared contact.
- Unload all wheels, equalize module elevations, tighten bolts, and recheck the seam.
- Adjust Bosch and front-facing RAS surfaces flush to the full 192-inch plane.
Stop condition
Never force one foot far enough to twist a plinth or open the seam.
Acceptance
Long straightedge and laser show one stable plane with no rocking.
Connect and level · straightedge and laser confirm one stable plane with every wheel unloaded - 110/4
Route and install Combo Tracks
Prerequisite
The complete plane remains stable through alignment and test cuts.
- Mark the final centerlines across the calibrated surfaces.
- Confirm stops cannot enter either blade path.
- Route shallow recesses for three 48-inch tracks.
- Install tracks flush and verify stop travel across working zones.
Stop condition
Do not route early; machine or seam adjustments would invalidate the recesses.
Acceptance
Tracks are flush, aligned, secure, and clear of every blade.
Combo Tracks · shallow recesses cut last, tracks flush, stops clear of every blade path - 120/4
Complete storage and commission
Prerequisite
Structure, machines, tracks, dust, and electrical paths are final.
- Fit remaining drawers, doors, shelves, pulls, removable panels, and dust details.
- Confirm no storage front blocks a foot, bolt, control, cord, or hose.
- Perform the full safety and definition-of-done checklists.
- Record baseline dimensions and photographs for future reassembly.
Stop condition
Cosmetic completion does not override a failed mechanical or safety check.
Acceptance
Station is rigid, mobile, serviceable, safe, and repeatably aligned.
Commissioning · storage fitted, dust routed, nothing blocking a foot, bolt, control, or hose
Safety gate
Safety before use
- RAS model, serial, recall remedy, and full blade guard are confirmed.
- All guards, anti-kickback devices, fences, and tables follow manufacturer instructions.
- All twelve wheels are visibly unloaded before either saw runs.
- Caster plates, pads, bolts, and LSL show no crushing, splitting, or pull-through.
- Modules are rigid, level, connected, and closed at the seam.
- Bosch and RAS tables are flush with adjacent surfaces.
- RAS faces front; crank, carriage, column, blade, guard, and hose move freely.
- Blade pullout latches behind its door and cannot enter a machine path.
- Electrical supply, breaker capacity, cords, and dust hoses are safe and serviceable.
- Combo Tracks are flush and stops cannot contact a blade.
- Long-stock support and the operator aisle are clear.
- Fasteners and calibration are rechecked after relocation or impact.
Commissioning
Definition of done
- Both modules are square, rigid, and free of twist.
- Each module rolls cleanly with all leveling pads retracted.
- All pads adjust from above and unload every wheel when deployed.
- Pins and bolts repeatedly return the seam to alignment.
- Bosch and front-facing RAS surfaces are flush with adjacent tops.
- The full 192-inch plane passes straightedge and laser checks.
- No control, blade path, crank, carriage, cord, hose, door, or pullout is obstructed.
- Modules separate without damage and fit the verified relocation route.
- All guard, recall, and manufacturer requirements are satisfied.
- Baseline measurements and photographs are saved.
Overall record
0 of 79 checks complete · 2 of 13 decisions closed