Just another cheap table saw upgrade table.

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Project by ediazf posted 11-13-2013 01:24 AM 3926 views 3 times favorited 13 comments Add to Favorites Watch

Well… just got tired of having to cut just a 32 cms (12 1/2 inch) rip, not to even think of cutting more than that, and just get stopped by the silly size of my table saw bed.

The whole thing is just made out of some good quality plywood, couple of nice hard oak planks under the plywood to keep it flat. I am thinking of building some kind of pivoting legs in the future if the thing starts to bow..

The router table part of the table is positioned just besides the aluminum table, so it shouldn’t put a lot of stress on the plywood.

The table itself was attached using some selftapping metal screws (countesunk) just to hold it while making sure the table front was perpendicular to the saw blade. Once tha was all secured in place, I attached permanently the top with 4 big bolts and nuts.

It has worked like a dream compeared to what it was before. The zero clearene insert is as good as an improvement as the table size itself. Not only the rip capacity is nice, but the front and back added space is also a nice unintended consecuence.

As you can see, I didn’t bother making a complex fixture for a table fence.. just the big framing square (one of my best firneds in the shop) and my trusty little straigt edge clamp. I will be making some kind of fence to attach to it so it is at least a couple of inches tall.

I have been following this site for well over 2 years and I think I might just start to post some of my project from now on.

FYI, I am from Chile, south america, so if my english is too bad, please be gentle :)

13 comments so far

View Dave Rutan's profile

Dave Rutan

1736 posts in 2387 days

#1 posted 11-13-2013 01:58 AM

Looks to me like you and I have the same table saw. I think you did a great job of extending its capabilities. I added a router table to mine recently for the same reason. (And your English is not bad at all.)

-- Ni faru ion el ligno!

View bigfoot11's profile


81 posts in 1881 days

#2 posted 11-13-2013 03:15 AM

Great upgrade!

I do imagine that the right side will sag over time, especially after you mount your router. Preparing for the sag and adding the legs now will always be easier than fixing it and trying to get the surface completely flat again later on.

View Ken90712's profile


17594 posts in 3387 days

#3 posted 11-13-2013 09:12 AM

Nice job on the upgrade…..

-- Ken, "Everyday above ground is a good day!"

View Oldtool's profile


2736 posts in 2389 days

#4 posted 11-13-2013 01:23 PM

Great improvement on the table saw, well done! Dual function – with the router mounting capability, and the zero clearance insert make this a top class saw.
I agree with bigfoot11 though, adding a supporting leg or two legs to the extension should be considered for safety reasons. Consider what might happen if you were to rip a small amount off of a sheet as wide as the table will allow: all the weight will be on the extension, and the saw might tilt over. Just food for thought.
Nice upgrade for sure, the problem solving ingenuity of woodworkers never ceases to impress me, and you’ve done that again.

-- "I am a firm believer in the people. If given the truth, they can be depended upon to meet any national crisis. The point is to bring them the real facts." - Abraham Lincoln

View ediazf's profile


19 posts in 2703 days

#5 posted 11-13-2013 01:31 PM

hahaha thanks everyone!

Yeah, I am going to add some legs or maybe even a drawer box or somthing.. with casters.

View Julian's profile


1398 posts in 2889 days

#6 posted 11-13-2013 03:18 PM

My first table saw was a black & decker similar to yours. The small table size made it very difficult to cut larger pieces. Looks like your improvement will work well.

-- Julian

View matts_dad's profile


61 posts in 2858 days

#7 posted 11-13-2013 04:12 PM

Looks very good so far – I would like to see what you come up with for the upgraded rip fence, and what your experience is using those wooden slots with a cross cut guide.

The weight of a decent iron top saw and an aging back led me to put an aluminum top saw in my basement shop. Except for the lack of a sore back, I am not pleased with the results: small top size, small fence and difficulty in maintaining flatness of top with the aluminum extension wings.

I hadn’t thought of building an entirely new top as you have done instead of adding some kind of an extension table. So, for selfish reasons, I encourage you to continue the good work, and share the results.

- I appreciate your post -

-- Barry

View CyberDyneSystems's profile


288 posts in 2387 days

#8 posted 11-13-2013 07:25 PM

Necessity = Invention.
way back when I first started my own contracting business,. I had zero to invest and just bought tools as I needed them. One of my first buys was a no name bench top saw that I paid $100.00 for new at a lumber clearing house.. I put in a good blade and it sufficed, but when it came time to turn some 4X8 laminated ply into cabinets, I always had to go back to my hand held circular saw and a straight edge.

This would have been a nice alternative!

-- Without the wood, it's just working

View ediazf's profile


19 posts in 2703 days

#9 posted 11-13-2013 10:54 PM

Crossut sled work perfectly.. The mitre slot on the aluminum saw was so tiny and its depth was so short, I had to keep pushing the sled itself downwards towards the table so it stayed on track… now I use the same sled but with a new much bigger oak runner and it works perfectly and smooter than before because the metal runner I had before had a little play in it.

The fence works just fine. I am getting pretty consistent width on my cuts front to back, so I don´t think I am going to be making a rail fence or something anytime soon.

View matts_dad's profile


61 posts in 2858 days

#10 posted 11-14-2013 03:20 AM

Aw shucks, I was hoping for another one of your good ideas. But, thanks for taking the time and effort to reply. If I do build something inspired by your work, I’ll put another note on this project.

-- Barry

View dnick's profile


986 posts in 2581 days

#11 posted 11-14-2013 04:27 AM

Really nice upgrade. Great job.

-- dnick, North Hollywood, Ca.

View SgtRed's profile


2 posts in 1976 days

#12 posted 11-15-2013 03:43 AM

This is exactly the upgrade I have been looking to perform on my small table saw{Ryobi}. Everyone else said I was crazy but I think you are dead on, the router may eventually cause sag, but I believe 3/4 Oak plywood is plenty to support the table saw components. Any tips before I start mine? things to avoid?

View ediazf's profile


19 posts in 2703 days

#13 posted 11-18-2013 02:07 AM

I would keep a little more plywood “meat” at the front/back end so I can campl easier some kind of jif or any new fence I might build

I think the router, if you put it right beside the aluminu tble, it shouldn’t be sooo much of a problem.

Nothing else. I learned that setting up the mitre slots to a particular size router bit is easier. Just one pass, and then it is only a matter of fitting the runner to it. The other thing, I found muuch better to embbed the runner on the sled or any jig with a dado. It stays and aligns perfectly straight and runs much smoother.

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