DIY Table Saw Outfeed Table

Tools Used:

• Bosch 12-Inch Miter Saw
• Ridgid HyperDrive 18v Brushless Brad Nailer
• Makita XPS01PTJ 18V LXT Track Saw Kit
• Makita Guide Rail, 55-Inch
• Makita Guide Rail Connector Kit
• DEWALT DW331K Jig-Saw
• DEWALT DW745 Table Saw
• DEWALT DW7440RS Rolling Saw Stand
• Kreg Jig K4 Pocket Hole System
• DEWALT DCK240C2 20v Lithium Drill Driver/Impact Combo Kit
• DEWALT DCS570B 20V Cordless Circular Saw
• DEWALT DWE6423K Variable Speed Random Orbit Sander

Materials/Supplies:

• Rok Hardware Leveling Feet
• Gourd T-Nut Leg Leveler
• Kreg Blue-Kote #8 Screw x 2″
• Gator Finishing 120 Grit 5″ Sanding Discs
• Gator Finishing 220 Grit 5″ Sanding Discs
• Minwax Polycrylic Water Based Satin
• 2″ x 4″ x 8′ – Lumber (12)
• 4′ x 8′ x 3/4″ Purebond Plywood (1)
• 4′ x 8′ x 1/2″ Purebond Plywood (1)

Measure Table Height

I start by measuring the height of the top of the table saw and then subtract the height of the adjustable feet and an additional ¾” for the plywood top.

Rough Cut Legs

I then take the 4x4s that I will be using for the legs and cut them down to rough length.

Square Up Two Sides

After that, I head on over to the jointer where I will make a few passes to square up two sides of the 4x4s.

Dimension the Legs

Then I take the 4x4s over to the table saw and trim the other two sides down so that I get a final dimension of 3” x 3” on the legs.

Trim 2x4s

The next step is to cut down all of the 2×4 material that will be used for the rails, bracing, and joists.

Dimension the 2x4s

Take all of the 2x4s over to the table saw and set the fence to remove ¼” from one side of each 2×4.

Once you trim ¼” from one side of each 2×4, reset the fence to remove ¼” from the other side of the 2×4 so that you are left with a 1 ½” x 3” dimension.

Assembling the 3 Sides

Front and back assembly begins with attaching the top and bottom rails to one of the legs, while the side assembly includes attaching the top and bottom rails to the other two legs.

Attach the rails to the legs for all 3 sides the same way, by predrilling out the holes for the screws, adding glue to the joints and then attaching with 2” deck screws.

Changing on the Fly

Originally the table was going to be 5′ wide, but it encroached into the center of the shop a bit more than anticipated. Being that floor space is a premium in a one-car garage, the decision was made to decrease the width from 5′ to 4’.

Implementing the Change

This change was easily accomplished because the 3 sides had not been attached yet so all that needed to be done was to take off 12 inches from the top and bottom rail of the front and back pieces with the circular saw.

Front & Side Assembly

Dry fit the front and side sections to ensure a snug fit and then continue with the assembly by pre-drilling, gluing and screwing the sections together with 2” deck screws.

Long Side Assembly

The last side is the long section that will run along the wall and act as a support for the extension wing of the table saw.

To make sure everything was square, screw one end of the top rail into the leg and then measured out the same distance as the opposing side rail and then glued and screwed the rail to the front leg using 2” deck screws.

Cutting the Joists

Start out on the miter saw cutting 2x4s to the length that will span the width of the frame and act somewhat as a joist.

Pocket Holes

Drill pocket holes for attaching the joists to the rails.

Attach the Joists

Attach the joists to the rails using 2” screws and used a speed square to make sure everything stays all lined up.

Continue Adding the Joists

Add the two joists that will support the bottom shelf, and then attached the last piece on the top.

Attach Front Rails and Feet

Use a speed square to find the center to predrill a hole to accept the small adjustable Teflon feet that will ensure that the table is rock solid.

Assemble the Front Legs

Assemble the left side of the extension wing frame with pocket hole screws and set it aside for now.

Attach the Front Legs

The next step is to attach the front leg to the top rail of the frame using pocket hole screws.

Add the Main Support Feet

The frame is put on its side so that the adjustable feet can be installed to all 4 of the main 3×3 legs.

Move Table Saw Into Place

It’s finally time to move the table saw into position and get the remainder of the frame together.

Extension Wing Support Pieces

After attaching the preassembled left extension section, head over to the miter saw to cut a few support pieces that will span between the left and right sections of the extension table.

Even More Pocket Holes

Then add a few pocket holes to the support pieces.

Attach the Support Pieces

Attach the support pieces to the frame using 2-inch pocket hole screws.

Level the Saw and Table

Make sure that the table saw and frame are level by adjusting the feet of the outfeed table and adding shims, if needed, under the table saw to line everything up.

Add a Top

Finally, it is time to put a top on this beast.

Wrestle a 4×8 sheet of 3/4 inch Purebond plywood onto the frame.

Marking Lines to Trim Top

Mark out the location of the table saw on the plywood so the cuts are accurate and the plywood could drop right over the table saw so there are no gaps.

The good thing about going from a 5-foot to a 4-foot table was that one solid piece of plywood could be used without having to piece together a few different pieces.

I dug through my toolbox and found one of a hundred spare dust collection elbows that don’t fit anything but never returned and used that as a template to match the rounded corners of the table saw.

Cutting the Straight Cuts

The straight cuts can be made with a track saw or circular saw and then finish off the corners with the jigsaw and a chisel.

Ripping the Trim

To make some trim for the short and long side of the table, rip down a 1-inch strip from one side of a 2×4 and then flip the board and repeat the cut on the other side.

Attach the Trim

Glue and nail the trim to the plywood top using 2-inch brad nails.

Sand the Top

Sand the top and legs down to 120 grit.

Apply Polycrylic Finish

Apply 3 coats of satin polycrylic, and lightly sand using 220 grit in between coats.