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Bosch 4100 Outfeed/Side Table Saw Extension

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Project by Michael J posted 06-13-2011 03:53 AM 14518 views 22 times favorited 12 comments Add to Favorites Watch

My table saw is a Bosch 4100 portable contractor saw. I am relatively new to woodworking and it seemed like a good choice at the time to get started with before committing to a full size cabinet saw, especially since my shop resides in my 2 car garage. With a think kerf Forrest II blade, zero clearance insert, crosscut sled and a dust collector bag underneath, I have not felt very limited yet as to what I’ve been able to do with this saw. I purchased the Bosch add-on side and outfeed table extensions, but those were of an open air design.

After using them for awhile, the open air design seemed like such a waste of space, so I starting thinking about ways to improve them. This is the design I came up with to make a larger table workspace. In addition, I was able to add a fold up table to increase the infeed depth when using my crosscut sled with it’s side extension for long boards. This allows me to get a full panel in the sled and move it back far enough in front of the blade safely without having to balance it on the table in front of the blade like I’ve done before. Believe me, these weren’t the safest cuts I’ve ever made on this saw. Overall, I’m very happy with how it came out and its been a nice modification that might put off the purchase of that cabinet saw a bit further into the future. Thanks for looking!

-- Mike Minneapolis, MN





12 comments so far

View Sonny's profile

Sonny

311 posts in 2598 days


#1 posted 06-13-2011 04:12 AM

that’s good lookin work man,,,,,,,,

View IceCactus's profile

IceCactus

43 posts in 1438 days


#2 posted 06-13-2011 06:43 PM

Really like what you did there. I have a Ridgid 2410 which is similar to your Bosch, and i have been trying to figure out how to do something similar as i want to make a large cross cut sled like you built. I have a need to cut some larger panels that i just cant do on the saw currently. The ridgid doesn’t have the extensions though so i have to figure out something else.

Where did you get the hardware for the folding part, the square tubes and brackets?

View Michael J's profile

Michael J

103 posts in 1952 days


#3 posted 06-13-2011 08:12 PM

IceCactus,
Perhaps you could figure out some custom solution similar to what this guy did here. Otherwise, you might want to see if you can replicate something similar to the Bosch setup. In fact, I would probably look at the Bosch manual and look up the dimensions for the Bosch vs. Ridgid and see if they are close. You could probably figure out a clever way to use the outfeed and side extension from the Bosch on your saw if the dimensions of the base are similar. I have to say, the additional table surface and flip up table has been far more handy than I originally expected. It also makes for a larger assembly work surface.

I found the parts at woodworker.com It’s important to use drop leaf hinges as the regular one’s will bind.

The part numbers are:
937-121 Drop Leaf Hinges
941-455 Slide out Leaf Support (square tubes and bracket)

-- Mike Minneapolis, MN

View IceCactus's profile

IceCactus

43 posts in 1438 days


#4 posted 06-13-2011 09:46 PM

Mike,

Thanks for the link, tips and the part numbers!

View AKAndrew's profile

AKAndrew

53 posts in 1520 days


#5 posted 06-14-2011 06:42 AM

that’s a really great idea, thanks for sharing

View rfroth's profile

rfroth

1 post in 956 days


#6 posted 05-06-2012 06:01 PM

This is exactly what I have been looking for. Do you have plans that you can share? I have the same table saw and gravity rise saw stand.

View Michael J's profile

Michael J

103 posts in 1952 days


#7 posted 05-11-2012 05:21 AM

rfroth,
Unfortunately, I don’t have any plans to share. I basically built it from scratch. The main thing is to use the Bosch table extensions. I used a cove bit to cut the grooves that hug the round bar of the extensions to support the table top. If you use the parts I listed above and the pictures, I think you should be able to do it pretty easily. If you have any questions, just let me know.

-- Mike Minneapolis, MN

View realpdm's profile

realpdm

2 posts in 951 days


#8 posted 05-16-2012 09:25 PM

I have this same saw and stand and this looks awesome. I think I will attempt something like this. Are the surfaces attached to the extension rails at all or just resting on the bars? Do you take them off before folding the saw up, or do you pretty much leave it setup most of the time?

I’m sure glad I found your post!

I have the Bosch sand for my miter saw as well. I’ve been pondering how to make some additions to it. this has given me some ideas. thanks again.

-- -pdm

View PAHunter62's profile

PAHunter62

6 posts in 704 days


#9 posted 01-14-2013 02:31 AM

Good idea Micheal. I just got the 4100, have the outfeed and left support coming tomorrow. I will probably make the sled with the kreg track too.

Thanks for the post.

View gladstone's profile

gladstone

1 post in 637 days


#10 posted 06-02-2013 02:48 PM

WOW! Just what I’ve been looking for. I got my 4100, stand and extensions about 4 months ago and have been thinking about something like this every since. GREAT JOB!!!. If you don’t mind me asking what did you use for the frame work underneath. 2×4’s?. What depth did you cut the coves? and lastly, looks like 3/4 melamine, am I right? And to mirror “realpdm” above are the surfaces attached or just resting on the extension bars? Would you mind filling me in with a little more details. Thanks and again GREAT JOB!!!

View RibsBrisket4me's profile

RibsBrisket4me

1414 posts in 1250 days


#11 posted 06-02-2013 02:59 PM

Very well thought out and executed. THanks for sharing!

-- http://www.PictureTrail.com/gid6255915

View Mambrax's profile

Mambrax

16 posts in 236 days


#12 posted 05-18-2014 01:52 PM

very nicely done !

-- Let's do the best we can !

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