LumberJocks

SawStop Outfeed Extension

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Project by TheMrWoody posted 04-15-2016 03:33 AM 2491 views 14 times favorited 13 comments Add to Favorites Watch

Finally got my upgraded 3HP SawStop setup and it was a great opportunity to add the must-have outfeed table extension.

Because I use the exterior garage door as the typical resting place behind my saw, I wanted to have enough of an extension for those typically shorter pieces. For the longer rips, I wanted the depth, but it had to get out of the way for keeping my usable garage space as efficient as possible. Since I’m in Texas, I get the benefit of opening the garage door 90% of the year, so a two-piece outfeed table made a lot of sense. Having a flip up outfeed table was a great combination when I need to open the door for the extra space and the flip up second half of the outfeed table added the extra support when needed (no more roller stands!).

Using Ted’s write up at http://lumberjocks.com/projects/43954, I got a head start. Because the 3HP SawStop is a full cabinet saw, I had the nice rigid backing to mount the support brackets for the first fixed section. I used these same “L” brackets for the pivot point that holds the secondary extension support piece.

The results was a deliberately svelte design that minimized the outfeed table bulk. I even used a foam core for the second (flip down) extension to reduce the weight. Since it didn’t need the miter gauge grooves, I was able to sandwich a foam core between two ¼” plywood pieces and then laminate the top and edges with maple. This makes the flip up a lightweight, one handed operation and kept the load down for easily moving the saw around on its mobile base.

The extension support comes from cutting a single piece of plywood in two and joining them with a hinge. The “folding” up in to the back of the saw keeps it out of the way and it auto-locks in the perfect support position when you flip the extension up for use without futzing with any adjustments – perfect every time. A quick, light tuck to the center of the support at the hinge allows it to fold down.

Details:
- Total extra outfeed: 13.5” + 13.5” = 27”
- Piano hinges used for the joints between the two extensions and at the pivot creating the support.
- Fixed extension section attached to the edge of the saw – Glued up two ¾” thick pieces of plywood, laminated on both sides. I router cut the miter slot grooves after mounted it in position.
- Second section – ¼” plywood on top/bottom of a ¾” core made of dense, rigid foam insulation board. The two ¼” pieces were slightly oversized to fit into ¼” grooves in the edging for rigidity.
- Edging – all ¾” maple with rabbited corner joints.
- Fixed Section Support Brackets – Used ¾” aluminum notched at each end to allow for bending an angle to enable mounting to the saw back and to the bottom of the fixed section of the outfeed table. I used threaded inserts for the bottom of the table for some adjustability via a slightly oversized whole drilled in the angle aluminum supports.
- Secondary Support – Pivots half way along its length. I used the lower part of the angle aluminum support to drill a pivot hole. I used threaded inserts in the sides of the lower part for the pivot bolts and small spacers to take up the space I created to allow for pivot-up clearance when you fold down the table (because the support piece folds up in between the two aluminum supports).

Slick, simple and very easy to use. With the secondary section folded down, the 13.5” of extra outfeed table is perfect for most situations and it doesn’t take up any more room than the clearance already required for the dust collector connection hose. It fits nice and close to the closed garage door. When I need the extra room, I either move the saw into the room or simply open the garage door.





13 comments so far

View WhoMe's profile

WhoMe

1471 posts in 2710 days


#1 posted 04-15-2016 01:29 PM

Ooo, really nice. If you don’t mind, I’m going to use yours as a design example for my SS outfeed table.
Gotta love that ics mobile base. I have the same setup and an loving the saw and the ease of mobility. Worth the minimal extra cost, imo.
Thanks for posting an excellent upgrade.

-- I'm not clumsy.. It's just the floor hates me, the tables and chairs are bullies, the wall gets in the way AAANNNDDD table saws BITE my fingers!!!.. - Mike -

View Scott's profile

Scott

150 posts in 2439 days


#2 posted 04-15-2016 01:33 PM

Me, too!

Nice job!

View jesinfla's profile

jesinfla

274 posts in 604 days


#3 posted 04-15-2016 02:48 PM

That’s sweet extension – grats on the build and thx for sharing

-- They said I could be anything... So I became Sarcastic! They also said making drawers is easy... I think they lied :(

View Ottacat's profile

Ottacat

426 posts in 1318 days


#4 posted 04-15-2016 03:17 PM

Very nice, lots of great ideas. Thanks for sharing.

View lizardhead's profile

lizardhead

609 posts in 2308 days


#5 posted 04-15-2016 04:23 PM

I need one of those

-- Good, Better, Best--Never let it rest---Always make your Good be Better & your Better Best

View helluvawreck's profile

helluvawreck

23199 posts in 2333 days


#6 posted 04-15-2016 04:43 PM

This large out feed table makes a very nice addition to your shop.

helluvawreck aka Charles
http://woodworkingexpo.wordpress.com

-- If a man does not keep pace with his companions, perhaps it is because he hears a different drummer. Let him step to the music which he hears, however measured or far away. Henry David Thoreau

View BurlyBob's profile

BurlyBob

3695 posts in 1732 days


#7 posted 04-15-2016 10:50 PM

That’s a great idea. Thanks for posting it. I’m in need of an out feed table and yours looks like a great variation.

View CL810's profile

CL810

3455 posts in 2455 days


#8 posted 04-15-2016 11:05 PM

Very nice. Thanks for posting. Favorited.

-- "The only limits to our realization of tomorrow will be our doubts of today." - FDR

View Mean_Dean's profile

Mean_Dean

5061 posts in 2614 days


#9 posted 04-16-2016 12:01 AM

Great looking outfeed table! I, too, need one of these!

-- Dean

View TheMrWoody's profile

TheMrWoody

18 posts in 621 days


#10 posted 04-16-2016 02:33 AM

Great feedback. Thanks. Glad it was useful.

Here’s a shot of it in the typical working position in the garage.

View Tetedebois's profile

Tetedebois

74 posts in 302 days


#11 posted 04-17-2016 10:42 PM

Nicely done! I need to build something similar for my new Sawstop too! Thanks for sharing.

-- Alex, Bas Saint-Laurent

View cracknpop's profile

cracknpop

195 posts in 1816 days


#12 posted 04-23-2016 12:56 PM

Great idea, great job. Thanks for sharing.

I see a drawer hanging from the side table attached to your SS. Curious, is that a SS side table or did you build it yourself? If SS, are you finding it is strong enough to carry the weight of the drawer and contents or did you add additional support?
I tend to move my SS with 52” fence around the shop but would like to have a drawer to keep SS accessories close at hand. Drawer like yours would be a good option.

-- Rick - I know I am not perfect, but I will keep pressing on toward the goal of becoming all I am called to be.

View TheMrWoody's profile

TheMrWoody

18 posts in 621 days


#13 posted 04-24-2016 02:41 AM

I have a 36” right side extension on my Saw Stop. In my show, it’s valuable space, so I added the drawer for close proximity access to the things like push sticks, feather boards, etc.

The table is the Saw Stop provided extension which is well made. The drawer adds some weight, but the front and back support system for the extension table is pretty beefy on the Saw Stop, so it doesn’t interfere with the lift (I bought the industrial base for the benefit of moving it any direction and the pump jack for lifting – great combo).

If I had the drawer add-on to do again, I’d make it wider and less deep (as in top to bottom), so you can get to things without digging through a pile. For weight distribution, the wider drawer version for the 52” table also makes for a better option. On the 52” table. I’d still suggest locating it closet to the base without interfering with the angle adjustment wheel as possible… if you’re on a mobile base. If you’re not on a mobile base, then I’d add a whole cabinet of drawers under the extension.

I have a Wixey saw fence digital measurement system on this saw, so I had to drop the drawer down a bit further to ensure it wasn’t in the way.

It was a great addition to the saw!

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