Table Saw Upgrades

This is the out feet table I made for my table saw a little while back. This has worked well for me over the past few months but what has never worked all that well was fence system on this saw. This seems to be a common problem on many lower end contractor style table saws. The current fence clamps on both sides of the table so I had to leave clearance on my out feed table for the fence to slide. I have been wanting to either buy or make a new fence for some time now. I decided since i have access to all the metal working tools i need at work, I am going to build one similar to the system John Heisz made for his homemade table saw project. Since this fence will only clamp on one side of the table i can make an out feed table that butts up to the table all the way across. I am also going to make the fence rail longer to bring my rip capacity up from 24'' to 36''.  

I am adding additional rip capacity so i decided to add a side table also. Here is what I came up with for the tables. I will do an additional post on building the fence system.

I started with some 2'' x 2'' aluminum angle that i attached to the back and side of the saw to act as a lip for the new tables to attach to. I slotted the holes to make the table adjustable so I could get it exactly flush with the table saw.

After the angle was installed with countersunk screws I made a brace from some scrap aluminum channel that I had on hand.

I cut a piece of aluminum to put on top so the wood frame would be supported by the brace.

Just temporarily installed with some regular screws.

Here is what it looked like once i put countersunk screws in everything.

Next I built a frame from 1'' x 4'' pine boards. I attached all the joints with pocket hole screws and glue.

The frame was screwed to the angle aluminum from the bottom.

Then I put plywood wrapped with pine edge banding.

The legs are just 2''x 4''s ripped in half with adjustable feet.

I made the feet out of scrap 3/4'' plywood. They are slotted and the leg has a hole drilled through it so the feet can be adjusted.

The slots extend out just like on my old out feed table.

I am really happy with how this project is turning out. This will make my table saw bigger and much more useful.

Thanks for viewing and hope you enjoyed.

Look for a post on building the fence soon!

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