Table Saw Outfeed Table #1: Fabricating the frame

So, I decided to build an out feed table for my table saw to make it easier to handle larger pieces of material. Because I am working with limited space – like so many others out there – decided to make it a fold away support. I had some old/new door hinges stored away so they are the basis of the geometry for folding the table down.

This is the frame design:

Of course – some changes were made once I got rolling. I really didn’t like the thought of having to remove so much of the support structure in the load bearing piece I would be mounting the hinges too. So I changed the design a bit by ripping the piece at 1 & 3/8 – the number I came up with by mocking up the assembly on the back of my saw.

I then ripped a thin strip the thickness of my blade – which just happened to match the thickness of the hinge plate and glued the piece back together with spaces for the hinges to fit into.

Here is the glued up support piece and the rest of the pieces needed for the frame. I need more clamps! :

Nice fit on the hinges:

Once the glued had dried I scrapped it and sanded the piece down for a nice finish and began assembling the frame. At this point I made another change to the design by adding further support to the hinge mounting area.

Notice the blocks closest to the saw – these provide both additional structural support (the top of this table will be 3/4” MDF – and a little heavy) as well as a way to secure the hinges to the frame.

You can see that the hinges are nice and snug against the frame:

Once completed this will change my table size from 27 to 60 inches :

-- - It's not worth doing if your not willing to do your best.