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Decked Out Ridgid Model R4511 Table Saw #7: A Breezy Side Extension Table

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Blog entry by Paul Stoops posted 12-27-2011 06:19 AM 6090 reads 4 times favorited 6 comments Add to Favorites Watch
« Part 6: Rear Outfeed Table Part 7 of Decked Out Ridgid Model R4511 Table Saw series Part 8: Relocating the Tilt Handwheel -- Design Considerations »

A Side Extension Table was required to fill the space between the front and rear fence support rails, outboard of the saw table. Some folks install a solid panel, as I did on my General 350 cabinet saw in my old shop because I had a multi-drawer cabinet underneath. Many folks use this space for a router table, which is a great way to add another tool to the shop without eating up any floor space. We have seen many great examples of this type of router table here on the LJ forums — it seems there are a lot of clever folks in the community willing to share their ideas and designs! I love looking at all of the various configurations and the skookum Yankee ingenuity! Whoops — and including our non-Yankee constituents…...... :-)

In that vein, I would like to thank the forum member who I think is here on LJ, for the inspiration for my take on a Side Extension Table. I copied a photo of your design, but I was unable to find your post when I was writing this blog — but whoever you are, thanks for sharing such a novel idea — you will recognize my version of your design!

I couldn’t bear to waste the space between the fence rails, but I didn’t need a router table since I will be building a free standing one soon. So when I saw the design of a Downdraft Sanding Extension Table , all the bells and lights went off! So here is my version of this accessory.

The downdraft table is surrounded by a removable fence system to help contain the sanding dust. Threaded tooling knobs with matching inserts secure the fence to the table and the fence components to one another. The table top is 1/2” Baltic Birch plywood covered in high pressure laminate. There are (432) 3/8” holes on a 1” x 1” grid, that were plunge routed through the top and finished with slight chamfers both sides to improve airflow. This hole pattern was designed to produce about 800 CFM airflow from my 3HP DC. A piece of perforated plastic shelf liner will be used under the workpiece when sanding.

The dust collection box is 21” wide and 27” deep, with 5” high maple side members. The bottom of the box is 1/2” plywood. Sloped baffles, on all four sides, made from 5mm Birch underlayment plywood, channel the dust down into a 1 1/2” x 14” center dust collection slot in the bottom of the box. Note the same aluminum duct tape I used to attach the baffles inside the saw cabinet in the earlier discussion.

A 6” diameter sheet metal right angle furnace boot with a 6” diameter PVC coupling was attached to the bottom of the dust collection box. The bar supported by the allthread pieces is a bumper to protect the thin sheet metal duct from damage when I roll my shop vacuum in under the dust box for storage.

This view shows the dust collection box installed between the fence rails. The laminate covered, perforated, 1/2” plywood top panel (slid aside) installs flush with the top of the box.

This view shows the modular fence components. They are designed so that one or both of the short sides can be removed to accommodate long pieces. If both short sides were removed, the long side would be clamped to the Unifence. However, most of the work I do should fit within the fences. The installation hardware is stored in one of the on-board storage drawers when not in use.

The modular fence components were designed to be stored underneath the dust collection box when not in use. Note the angle clips used to secure the dust collection box to the fence rails.

Again, my thanks to the forum member who posted the original design. One of the things I most enjoy about the LJ forum and others is the sharing of ideas that others can use and hopefully improve upon and/or adapt for their own use. What a great woodworking community!!

Well, that’s about it for this chapter. Hang in there….....................there’s a lot more to come. Thanks for stopping by. Please feel free to leave any comments or constructive criticisms. All questions will be answered.

-- Paul, Auburn, WA



6 comments so far

View NormG's profile

NormG

4537 posts in 1755 days


#1 posted 01-02-2012 06:16 AM

You have done a wonderful job of planning the refitting and just as good of a job photo journalism of the whole process. Very useful additions

-- Norman

View Paul Stoops's profile

Paul Stoops

324 posts in 1312 days


#2 posted 01-02-2012 06:35 AM

Thanks, NormG for your kind comments. —It was a fun project and it works as well as it looks….... :-) Photo documentation is really easy these days with the advent of high quality, affordable digital cameras. I notice that a lot of folks here on the LJ website are doing super jobs of documenting their projects. I love to see the wonderful pics of other folks’ projects.

-- Paul, Auburn, WA

View whitebeast88's profile

whitebeast88

3603 posts in 942 days


#3 posted 06-29-2013 10:10 AM

WOW!!!!thats very nice,great build.

-- Marty.Athens,AL

View Buckethead's profile

Buckethead

1951 posts in 620 days


#4 posted 06-29-2013 10:58 AM

Excellent build, and share! The extension looks marketable.

-- Bucket, any person that spends 10k on a bicycle is guaranteed to be a $@I almost started to like you. -bhog

View rustythebailiff's profile

rustythebailiff

92 posts in 693 days


#5 posted 06-29-2013 01:23 PM

It’s so nice, it looks like you bought it out of a catalog. Excellent attention to detail

-- "Necessity is the mother of invention"

View Paul Stoops's profile

Paul Stoops

324 posts in 1312 days


#6 posted 06-29-2013 02:54 PM

Thanks guys for your kind comments. It was a fun project. I haven’t been able to try out the downdraft table yet, but I hope to soon. I will post the results after I use it.

-- Paul, Auburn, WA

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