Table saw extension for DWE7491RS saw

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Project by BOBAH posted 09-03-2018 07:26 AM 908 views 0 times favorited 3 comments Add to Favorites Watch

I have relatively small in-garage shop and try to keep my power tools mobile or foldable as much as possible, so upgrading my contractor-grade DeWalt table saw to a cabinet saw is a step I am not yet ready for. However, the limitations of contract saw are pretty clear, like rip capacity (though decent 32”) and limited support for the long pieces when cross cutting. I was looking for a DIY solution for DeWalt saw all over internet, and all I found were full-size cabinets with a saw dropped in. I already have permanent outfeed/assembly table, so building another cabinet seemed an overkill, so I ended up adding this removable extension that gives 40” of support to the left of the blade – in addition to 32” to the right.

No saw modifications are involved – the base pinches the tube frame with four 1/4” bolts, and the top rests on that base.
The level of the top is adjustable with the wrench, and the whole thing can be detached in a few minutes. The triangular hole in the right side of extension table provides access to the lever that releases riving knife.

I used 3/4” birch plywood for all parts. The top is stained with red cherry+golden oak mix stain (to match my fence), finished with spray lacquer and layer of wax.

Today I used it to cross-cut long 6/4 birch boards to size, using Incra miter gauge – works very well, safe and precise, no need to pull out circular or miter saw for rough cutting.

3 comments so far

View recycle1943's profile


2177 posts in 1742 days

#1 posted 09-03-2018 09:54 AM

good safe thinking – sure makes a little saw ready for big jobs

-- Dick, Malvern Ohio - my biggest fear is that when I die, my wife sells my toys for what I told her I paid for them

View dannmarks's profile


603 posts in 701 days

#2 posted 09-03-2018 10:34 PM

Yes you turned it into a $1000 unit. Keep a sharp blade on it and it will be great.

View mcoyfrog's profile


4389 posts in 3714 days

#3 posted 09-04-2018 02:01 PM

I was out in the shop yesterday and told myself once again I need to get a outfeed and side table built for my table saw. This one is great have fun

-- Wood and Glass they kick (well you know) Have a great day - Dug

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