Outfeed-Assembly Bench #1: The start and the BIG mistake

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Blog entry by JasonK posted 02-19-2008 06:36 PM 2443 reads 0 times favorited 10 comments Add to Favorites Watch
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So , my last project has turned into a bit of a disappointment. I’ve been working on a new outfeed/assembly table to sit behind my tablesaw. I had a plan in my head, I’d bought my plywood for the carcass and had an old hollow core door for the top. I was so proud of myself. Instead of rushing through and fixing my mistakes as I went, I spent some time with SketchUp to get a basic idea of what I wanted then put pencil to paper. I measured the height of my table saw then measured all of the dimensions of all the individual cabinet pieces and I was ready to go. I ran upstairs, grabbed the computer away from my wife, quickly found a website that would do fractional math, punched in all of the dimensions and ran back down to the shop determined to get the carcass build that night. I was finally ready to go.
I started with the carcass…

Oops Carcass

Then modified the hollow core door…

Oops Top

Got the carcass up on sawhorses, mounted the casters, trimmed out the plywood edges and even got a coat of paint on the outside…


Then it happened. Oops!

Oops Saw Front

You can only imagine my frustration and disapointment at this point. In my haste to “punch” all of the dimensions in to the computer, I completely forgot to include the dimension of the casters.

The solution, which, for the record, I’m not at all happy with, is to remove the casters. Luckly, I had enough just enough room to screw on a few of those little plastic furnitire sliders so the plywood isn’t sitting directly on the concrete floor.

The second solution, (and morale of today’s story) a ProjectCalc Plus for $16 at Lowe’s.

If anyone has any other ideas on how to remedy this mistake, feel free to chime in.

-- Measure once; Cut Twice, Three Times, Four Times...

10 comments so far

View Peter Oxley's profile

Peter Oxley

1427 posts in 4960 days

#1 posted 02-19-2008 06:40 PM

Oh, man! I feel your pain! This kind of thing happens to everyone now and then. Maybe put the saw on a mobile base and put smaller casters on the the outfeed bench?

-- -- --

View GaryK's profile


10262 posts in 5074 days

#2 posted 02-19-2008 06:49 PM

Been there, done that!

I would take the top off, cut it down, put the top back on and put the casters back on.
Cut the top end so that it won’t be seen under the over hanging table top.

You could also add little extensions on the sides of the box and mount your wheels on the outside instead
of under the bench.

No one will ever know.
Well except everyone in the world who as seen this post and we won’t tell :-)

-- Gary - Never pass up the opportunity to make a mistake look like you planned it that way - Tyler, TX

View Scott Bryan's profile

Scott Bryan

27249 posts in 4908 days

#3 posted 02-19-2008 06:49 PM

Don’t feel so bad about this, I know it is frustrating but guess what I did the same thing. But in my case my legs were made out of 2×4s and screws and took it apart and trimmed the legs to match my saw height.

Obviously you can’t do that here but one thought I had When I was building my table, but could not quite work it out, is on a episode of the NYW Norm build an assembly table that was mobile when the casters were down. However it had supports that let the caster rotate up and out of the way when the supports were removed. This might be something to consider here. With the casters up the table would be sitting on the floor and be rock steady.

This would be project # 0207.

Just a thought.

-- Challenges are what make life interesting; overcoming them is what makes life meaningful- Joshua Marine

View Blake's profile


3443 posts in 4960 days

#4 posted 02-19-2008 08:07 PM

I did this with my router table. It ended up just a little higher than I had planned. I have gotten used to it. But you aren’t the only one who has made this mistake for sure!

-- Happy woodworking!

View Patrick Jaromin's profile

Patrick Jaromin

412 posts in 4918 days

#5 posted 02-19-2008 08:48 PM

I’ve made similar mistakes as well…and unfortunately am likely to again. I’m with Scott—I’d try to rig up an outrigger for the casters. Then you get the best of both worlds and can tell everyone—“Yeah, I planned it that way!”

-- Patrick, Chicago, IL

View Thos. Angle's profile

Thos. Angle

4444 posts in 5048 days

#6 posted 02-19-2008 09:03 PM

Gee, I’ve never made a mistake like that!!!! LOL

-- Thos. Angle, Jordan Valley, Oregon

View Ethan Sincox's profile

Ethan Sincox

767 posts in 5260 days

#7 posted 02-19-2008 09:15 PM

Put your TS on castors, too?

(Sorry, but someone had to suggest it…)

-- Ethan,

View Partridge's profile


296 posts in 5042 days

#8 posted 02-19-2008 09:21 PM

Yes it would be possible to cut the top off .{with scribe and skill saw with fine blade} then pocket hole screw will finish up. I have done worse. at leases you have to much and not to lease

-- I get out in the shop when I can

View rpmurphy509's profile


288 posts in 4940 days

#9 posted 02-19-2008 11:41 PM

I had to laugh after the first mention of castors.

I did the exact same thing a couple years back
making a small cabinet/outfeed support for my
little contractors saw. After slapping them on the base
and setting it next to the saw took me an hour
of redoing my math to figure out the wheels are what
threw me off track.

I’ll probably do it again….

-- Still learning everything

View Grumpy's profile


26812 posts in 4937 days

#10 posted 02-20-2008 12:27 AM

Jason there are some good ideas above which would provide a solution. You might have done yourself a favour, that assembly table will sit on the floor solidly without the castors, hence less risk of injury & easier to work on. Have you thought of attaching the wheels on the outside & build a mechanism to rotate the wheels underneath when you want to move it around. I saw something on New Yankee Workshop where a cabinet makers factory had none the same thing. good luck whatever you do.

-- Grumpy - "Always look on the bright side of life"- Monty Python

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