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Table Saw Adjustable Extension support Details

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Blog entry by Robsshop posted 1246 days ago 3627 reads 18 times favorited 14 comments Add to Favorites Watch

I have had some interest from a few L J’s on a TS feature built into My saw’s fence extension rail. One Member suggested that I put together some details and pics and enter it as a Blog, so here it is. This is My first Blog, so I hope I can make sense of this simple but useful TS fixture. It consists of a few easily fabricated pieces that can be be put together with very little difficulty and can be adapted to most TS’s with hollow extension fence rails !

The main beam that rides inside of the TS extension tube is what supports the front of the SIDE SUPPORT RAIL and is constructed with two halves of hard wood stock and 1/4”x2” aluminum flat stck. that is cut to fit and screwed together forming a beam. Length is determined by the length of Your front rail and how far You can extend it with retaining good support of the material being cut( i.e. sheet goods/ large width stock ). I can extend my side support out to about 40” and support the weight of a full sheet of MDF with little deflection. When constructing the beam I made sure to leave a dado space on the bottom side to avoid any mounting bolts with in the saw’s rail ! Over all length of My beam is 6 ft. !


The SUPPORT RAIL is attached to the beam’s end and is made up of aluminum flat stock and hard wood plank mated together, that is aligned with the TS surface! ( I add a riser strip when using My CC Sled to match the sleds additional height). {TIP} When attaching in to the end grain of the beam I inserted dowel plugs for the screws to hold better.The back half of the SUPPORT RAIL is made up of two parts. The first is what I will call a support rod, It is what tracks, holds and locks the rail in place via thumb screw at TS’s out feed side rail. It is just a 3/8” metal rod and the length is determined by how much travel You have designed into Your beam.(My rod is 48”). Second part, the SUPPORT RAIL when in use is held up via folding table leg and supports the back half of the rail. When not in use the rail slides compactly against the TS and the leg is folded up and held in place with tension from the U-shaped bracket and bolt.


Well that is pretty much it, I hope I have explained the basic concept for those interested and that it is something you can adapt to Your TS. It is simple but affective, I can Cut 4×8 sheet goods with ease and set up takes seconds !

Thanks for taking a look and if any more details are needed, please feel free to ask !! ROB

-- Rob,Gaithersburg,MD,One mans trash is another mans repurposed wood shop treasure ! ;-)



14 comments so far

View Rick  Dennington's profile (online now)

Rick Dennington

3272 posts in 1796 days


#1 posted 1246 days ago

Hey Rob,

WOW….. that is really a slick set-up. I have a Unisaw, but have never thought about doing something like this….it is really neat. Did you come up with the construction of it by trial and error, or just jump in and build it?.....lol. I have outfeed tables all around my saw, but this is highly unusual…..Stellar job, my man….. Rick.

-- " I started with nothing, and I've still got most of it left".......

View Robsshop's profile

Robsshop

807 posts in 1577 days


#2 posted 1246 days ago

Hey there Rick, Thanks for the comments and it did take some brain storming to get it right but actually pretty simple once I came up with the concept ! It really helps with sheet goods and long stuff. Glad to see You in the shop again !! Thanks again and take care ….. ROB

-- Rob,Gaithersburg,MD,One mans trash is another mans repurposed wood shop treasure ! ;-)

View woodworm's profile

woodworm

14124 posts in 2192 days


#3 posted 1246 days ago

That is really cool!....not less important you know where you can get all those stuff and you got ‘em.
Great work Rob!

-- masrol, kuala lumpur, MY.

View Rick  Dennington's profile (online now)

Rick Dennington

3272 posts in 1796 days


#4 posted 1245 days ago

Hi Rob,

I went back and took another look at your saw set up, and noticed your shop cabinets….this time..lol.
Those are nice. Did you build them, or did they come out of your kitchen, or what? I have an old workbench

that I need to replace (probably one of the first I built 25 years ago), and I like the design of cabinets like yours…....Roomy!!! Once again, you’ve showed out….lol. Stellar job, as usual, Rob.!! Rick.

-- " I started with nothing, and I've still got most of it left".......

View Robsshop's profile

Robsshop

807 posts in 1577 days


#5 posted 1245 days ago

@RickDennington….. The cabinets are actually a rare find that a GOOD friend (who happens to be in real estate) turned me on to ! He had gone to a foreclosure auction (new home developer gone bust !) to see if he could nab a hand full of cabinets for his garage upgrade and when he won the bid ( for $500) he discovered that he had bought an entire kitchen cabinet upgrade, brand new still in the boxes ! Approx. 22 cabs of different sizes, floor and wall units. He asked Me if I could use some top grade cabinets for my shop, I replied “Too rich for My blood” and He said how about $100 bucks for everything, except the Five or so he needed ! Well when I picked my jaw up off the floor, I was the new proud owner of what You see,actually there are several in my shop addition ( not pictured yet) and yes they have come in real handy when it comes to storage ! I also have turned a few into mobile carts for some of my power tools as well ! If You set out to build some for Your own shop, it would only be fitting for a shop as nice as Yours Rick !!LOL Thanks and good luck…..ROB

-- Rob,Gaithersburg,MD,One mans trash is another mans repurposed wood shop treasure ! ;-)

View Rick  Dennington's profile (online now)

Rick Dennington

3272 posts in 1796 days


#6 posted 1245 days ago

Thanks for the reply back, Rob….That explains everything clearly…...WoW…...what a score. Wish I knew someone in real estate….lol. Boy I tell ya what…you found a birdnest on the ground….Thanks again, and keep posting them projects…...!!!

-- " I started with nothing, and I've still got most of it left".......

View bigike's profile

bigike

4031 posts in 1890 days


#7 posted 1245 days ago

very neat idea, now I just need the space in my shop.

-- Ike, Big Daddies Woodshop, http://www.icombadaniels@yahoo.com

View Robsshop's profile

Robsshop

807 posts in 1577 days


#8 posted 1245 days ago

Big Ike, Thanks and it was lack of space that got this upgrade on and then off My to do list !! LOL

-- Rob,Gaithersburg,MD,One mans trash is another mans repurposed wood shop treasure ! ;-)

View ken_c's profile

ken_c

260 posts in 1764 days


#9 posted 1245 days ago

Thank you thank you thank you!!! I have a similar thing laying around from the GI saw i just sold. I need to modify it to fit the new unisaw and you have shown me the way. Again, Thank you. I now know I don’t need to worry about the mortise and tenon holding mine together, since i need to take it apart to re-machine the tube insert to fit the unisaw. I can just cut it and add a strap similar to your design.

View Robsshop's profile

Robsshop

807 posts in 1577 days


#10 posted 1245 days ago

My pleasure there Ken, good luck and be sure to post some pics when finished !!

-- Rob,Gaithersburg,MD,One mans trash is another mans repurposed wood shop treasure ! ;-)

View ChunkyC's profile

ChunkyC

856 posts in 1856 days


#11 posted 1243 days ago

Awesome Rob! Thanks for posting this.

-- Chunk's Workshop pictures: http://spadfest.rcspads.com/thumbnails.php?album=135

View Robsshop's profile

Robsshop

807 posts in 1577 days


#12 posted 1243 days ago

No problem Chuck, hope it works out for Ya !

-- Rob,Gaithersburg,MD,One mans trash is another mans repurposed wood shop treasure ! ;-)

View Jim Jakosh's profile

Jim Jakosh

11086 posts in 1707 days


#13 posted 1169 days ago

Very cool. I love innovation like that. I thought I had a good outfeed support, but that is awesome!!!!!!!

You really put some thought and engineering into that one!! Thanks for sharing. If I had the room, I’m ake one like yours!!.............Jim

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View Robsshop's profile

Robsshop

807 posts in 1577 days


#14 posted 1169 days ago

Thanks Jim, I came up with the idea to solve the issue of limited side support, especially when cutting sheet goods. The nice thing about the system is it doesn’t take up much room when tucked away and can be pulled out as far as needed. Thanks again for taking a look !..........ROB

-- Rob,Gaithersburg,MD,One mans trash is another mans repurposed wood shop treasure ! ;-)

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