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Table saw extension for DWE7491RS saw

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Project by BOBAH posted 09-03-2018 07:26 AM 1275 views 1 time favorited 5 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.





5 comments so far

View recycle1943's profile

recycle1943

2428 posts in 1794 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

dannmarks

645 posts in 754 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

mcoyfrog

4504 posts in 3766 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

View YannickR's profile

YannickR

1 post in 36 days


#4 posted 10-09-2018 07:48 PM

Hi Bobah, I have a small 14’x 18’ garage and with my copie of JayBates MiterSawStation I have to be smart about the space I have left. Like you, I don’t have the cash or the space for a full size table saw cabinet. So your table extension look’s really thought out and seems to be very functional compared to many I’ve seen on the web also. I was going to copy off of this nice extension which I found will reading the Dewalt reviews on Amazon… https://www.amazon.com/gp/customer-reviews/R241IILQRK4WN4/ref=cm_cr_getr_d_rvw_ttl?ie=UTF8&ASIN=B00F2CGXGG
Just like you, I have a small 14’x 18’ garage and with my copie of JayBates MiterSawStation I have to be smart about the space I have left. I don’t have the cash nor the space for a full size table saw cabinet. Finally, here’s my question… I’m pretty visual and I have a hard time figuring out how you actually “pinch” the base tube with the plywood base! It look’s like the table base is just wedged underneath the tubing not bolted down but leaning on it’s own weight to hold it in place! Is my assessment correct or Could you put up a couple more picture’s from underneath and around that base and maybe some detached from the Saw. A video would be awesome I you’d take the time but I’m new to LumberJocks and don’t know if this could be done. Thanks

View BOBAH's profile

BOBAH

101 posts in 1515 days


#5 posted 10-11-2018 06:07 AM

Hi Yannick. You might be right, there is not much pinching involved. If I remember correctly, the whole base mostly lays on the frame tubing. It became super sturdy when I added vertical front and back supports and attached the top, so the base stays wedged in place.

Recently I have added two legs and stretcher to support the outer edge to eliminate slight flexing when heavy material is being cross-cut.

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