Converting the Knockdown Saw Horse to a Full Sized Outfeed Table

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Blog entry by grovemadman posted 02-17-2008 03:08 AM 7502 reads 0 times favorited 8 comments Add to Favorites Watch

Wouldn’t it be great if you could take a small tabletop saw or midsize contractor saw to a jobsite and have a full sized outfeed table similar to a production shop? The kind of outfeed that would breakdown and set up quickly and store out of the way if needed on a daily basis, and not waste time consuming labor? Of course it would. Here is an Idea I had about the knockdown sawhorse I made the other day.

I will make this blog into a small series and I will be open to new ideas and thoughts so we can all enjoy the project and fulfill our needs individually. The first problem I came across is the height of the saw and how level it is. (Figure 1c) While I made my sawhorse/table hastily, I hadn’t planned on the outfeed table just yet. Now I would like to add it. To do this I will probably use aluminum angle mounted the tablesaw and to the cleats, and it will just drop in place and fasten with wing nuts from underneath. A rubber or foam gasket betweeen the Angle pieces should reduce any vibration and I expect there will be. The next problem I noticed was the length of the cleats. They will have to be longer with a possible third leg added to the back side so we can have more outfeed length. Also I would like to have the saw mounted in front of the front leg so I can get to the knobs safely. We could build this truss style or like my friend John and I plan on doing is making a fold up table with formica on one side so our wood flows smoothly through the blade. Our top would Ideally have a recess in it that drops around the saw manufactures table, and so we could incorporate zero tolerance blades inserts. And finally we would want to have some kind of dust collection we could quickly remove. We decided a board or even better, clear plexiglass with a hole in it hooked up to our shop vac would be the nicest option.

Overall we feel we have come up with some good ideas that will still enable the system to be set up in less than five minutes and have our cleats & legs stow away taking up a minimum of space. We think were gonna have our cake and eat it too on this project, but we’ll have to wait and see about that! In the next segment we will discuss some of our engineering pitfalls, give you a progress report and convey any new ideas we may have come up with through other members or ourselves (see photo examples)

! (knockdown sawhorse)!
! !

-- "It is the job of the woodworker to hide his mistakes and keep a tight set of lips about them!"--Chuck

8 comments so far

View CharlieM1958's profile


16292 posts in 5458 days

#1 posted 02-17-2008 03:56 AM

Okay, you dream big. Now let;s see if you can deliver, Chuck. :-)

-- Charlie M. "Woodworking - patience = firewood"

View Scott Bryan's profile

Scott Bryan

27249 posts in 5062 days

#2 posted 02-17-2008 04:57 AM

Good idea Chuck. I too have been pondering this for some time. Something like this would be nice for small shops like mine. Outfeed tables are, in my opinion, an essential safety device. I personally do not like roller stands. I will use them out of necessity but they don’t work very well. But these ideas are far more complex than anything I could ever conceive. They certainly are ambitious.

Let’s see what you come up with.

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

View grovemadman's profile


963 posts in 5012 days

#3 posted 02-17-2008 06:05 AM

I’ll do my best. I’ll have some time soon to start this and I know I can do it if I put my mind to it and take my time. When I do it will be nice. Hopefully it will help somebody else too!

-- "It is the job of the woodworker to hide his mistakes and keep a tight set of lips about them!"--Chuck

View teenagewoodworker's profile


2727 posts in 5008 days

#4 posted 03-23-2008 04:27 AM

good idea. is it something along the line of this that you are thinking of. >go to Table saw stands >go to PortaMax Model 2775

(sorry it wouldn’t let me get a link to the exact page)

you can also get a table extension and an out feed table. turns a bench top model into everything that the cabinet models have. you can get an out feed table for it and an extension to bring the fence to 52in (you can also get a router table in the extension.

send me a message if it is. sounds like a cool project.

View grovemadman's profile


963 posts in 5012 days

#5 posted 03-23-2008 05:44 AM

No Lad. Make your own! Check out my blogs / Knockdown sawhorses. These are so easy to make a monkey could do it. You have the tools and skills to make a set of these in about an hour. Actually look in my projects you can find it there. Copy???

-- "It is the job of the woodworker to hide his mistakes and keep a tight set of lips about them!"--Chuck

View Pretzel's profile


93 posts in 4986 days

#6 posted 04-07-2008 10:46 AM

how’z the table coming? would like to see it, any new updates?

-- Pretzel L8agn

View grovemadman's profile


963 posts in 5012 days

#7 posted 04-07-2008 11:22 AM

I can’t afford the wood/parts right now. Pursestrings are tight as ol’ Bejamin Franklin would say. I will keep you posted though as soon as I can get back to it. I got bigger fish to fry or I’ll be homeless soon!!!!! (:>O

-- "It is the job of the woodworker to hide his mistakes and keep a tight set of lips about them!"--Chuck

View AJ1104's profile


1362 posts in 2899 days

#8 posted 03-14-2021 12:02 AM

Tremendous idea! Go for it!

-- AJ

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