Tablesaw Extension, Crosscut Sled, and Storage Cart

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Project by Mark Brown posted 01-25-2015 12:14 AM 12934 views 52 times favorited 13 comments Add to Favorites Watch

With my brother’s help, I was able to finish up a few projects last month. I was fortunate to get a new Sawstop Industrial Cabinet Saw last year and had been wanting to make a few accessories. After getting inspiration from screwge ( ), I added a sliding extension using 1 1/4” telescoping Aluminum tubes with a Maple runner. The tubing was connected to the saw with eight machine screws. We drilled several holes in the tubing and treaded them using a ¼” tap. I trimmed the screws so they wouldn’t interfere with the inner tubing. I added one long screw and the end of each tube as a stop and also to add additional holding strength if it’s fully extended. The runner is made from maple and attached using 1/2” bolts that screw into a piece of solid aluminum square block that was press-fit into each end. I slotted the holes in the maple runner so that I could raise the height 1/2” if I was using my new crosscut sled and needed additional support. The runner can be extended any length up to 48”.

The design for my crosscut sled came from Shan ( ). I used Kreg’s 3/4” miter gauge fixture bars and their heavy duty Track. It took me several tries to install the miter bars since the screws were installed from the bottom and there isn’t much room for error. After several attempts, I finally got them spaced correctly by cutting a piece of scrap plywood that was the exact width of the distance between the slots. I installed the first bar just using a square. Then using the plywood spacer I was able to align the second bar. I used the 5-cut method to square the back fence. It works great. I went years without a good crosscut sled. Now that I have one, I don’t know why I waited so long because I use it all the time. It’s also a good rust preventer:), since I just leave it on top of the saw when not in use.

My last project was a storage cart that I could use to store my saw blades and accessories. I wanted to take advantage of the space under the extension wing, but I also needed it to be on rollers to that I could still move my table saw. Once I made that decision, I decided I could also use it as an assembly/clamp table, so I added the Kreg Klamp traks. The top is made from oak butcher block that was left over from another project.

The cabinet is attached using two brackets on the back that are slotted. I added the slots so that I can secure the cabinet (from moving in/out when I open/close the drawers), but still allow the table saw to be jacked-up and moved around (with the cabinet).

I would also like to thank Dan ( ) for the design inspiration.

Thanks for looking.

-- Mark, Pearland Tx

13 comments so far

View bushmaster's profile


4164 posts in 3614 days

#1 posted 01-25-2015 02:02 AM

I like your setup with the saw, roller extention table is very nice for plywood. How do you manage no sawdust on the floor.

-- Brian - Hazelton, British Columbia

View txn's profile


147 posts in 2791 days

#2 posted 01-25-2015 02:24 AM

Could you post some pics of how you attached the cabinet to the extension wing. I need one of those

View English's profile


693 posts in 2809 days

#3 posted 01-25-2015 12:42 PM

Nice setup. I need to do this to my Saw Stop!!

-- John, Suffolk Virgina

View Woodbridge's profile


3751 posts in 3750 days

#4 posted 01-25-2015 02:33 PM

fabuluos set-up.

-- Peter, Woodbridge, Ontario

View Ken90712's profile


18096 posts in 4520 days

#5 posted 01-25-2015 04:34 PM

Sweet about to buy a Saw Stop 3Hp how do you like yours. Man your shop is clean.

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

View Mark Brown's profile

Mark Brown

11 posts in 4025 days

#6 posted 01-25-2015 08:18 PM

txn: The Cabinet is attached using a couple brackets that are attached to one of the support boards under the extension wing. The vertical slots allow me to raise and lower the saw without having to also pickup the cabinet. I used a couple knobs to hold it in, but I keep them loose so they don’t bind up when lifting the saw. To remove the cabinet, I simply remove the 2 knobs and roll it out. To reattach the cabinet, I roll it back in and use the wings on the brackets to help align the cabinet, then I reinstall the knobs.

-- Mark, Pearland Tx

View Mark Brown's profile

Mark Brown

11 posts in 4025 days

#7 posted 01-25-2015 08:31 PM

Ken90172: I really like this saw. My previous saw was a Delta 10” Unisaw with a 52” fence which I had for 12+ years. I really didn’t have any issues with the saw, but I started considering the Sawstop when a friend of mine asked to borrow my pressure washer because a friend of his cut-off a couple fingers while installing flooring.

I was raised to always respect the power of tools and fortunately, in the 30+ years of using a tablesaw, I have never had an accident like this. However, this accident did make me stop and think. As with most people, my hands are essential to my job (IT Project Manager) and as I get older I’m concerned I could make a critical mistake.

I may have initially looked at the Sawstop because of it’s safety features, but I decided to buy it based on it’s quality. The fit and finish is excellent. No vibration. The fence is perfectly square to the blade. I have consistently cut 1 1/2 maple with no issues.

My expectation is that I will never need the safety feature, but it’s nice to have the insurance.

-- Mark, Pearland Tx

View Robsshop's profile


923 posts in 4307 days

#8 posted 01-26-2015 12:28 PM

Nice trifecta on your TS station, I like your roll out storage/work station. I built a side extension very similar to yours into my Unisaw years back and absolutely love it. Your CC SLED looks like a winner as well. Thanks for sharing…....Rob

-- Rob,Gaithersburg,MD,One mans trash is another mans wood shop treasure ! ;-)

View DrJMB's profile


1 post in 2335 days

#9 posted 08-27-2015 02:13 PM

Very nice work and additions to saw. I’m just starting to reinvent my workshop and these look like great ideas. That outfeed roller area is great. Is that purchased or did you make it? My Laguna Fusion table arrives today. I’m limited to 120VAC. I’d like to use some of these ideas.

View jciccare's profile


30 posts in 2599 days

#10 posted 01-26-2017 01:40 PM

Mark, this is an elegant version of screwge’s sliding TS extension—I’m leaning toward adapting it to my Craftsman 22124 hybrid.

You write “I added one long screw [at?] the end of each tube as a stop and also to add additional holding strength if it’s fully extended”. I’m trying to visualize where that long screw could be located, and how it can function as a stop, assuming the inner and outer tubes are square-profile.

-- Accomplish the great task by a series of small acts. (Tao Te Ching / Lao Tzu)

View will's profile


6 posts in 5100 days

#11 posted 03-25-2019 12:24 PM

What did you use for the rear extension tube and what does it slide in? Thanks

View WayneC's profile


14359 posts in 5429 days

#12 posted 03-25-2019 03:16 PM

Great addition to your saw.

-- We must guard our enthusiasm as we would our life - James Krenov

View Mark Brown's profile

Mark Brown

11 posts in 4025 days

#13 posted 03-26-2019 12:21 AM

Will, the front and rear extensions are the same. I used telescoping aluminum tubes (one fits inside the other). I mounted the outer tube inside the fence tube and the rear was mounted on the angle iron that is used to support the extension wings.

-- Mark, Pearland Tx

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