Table Saw Extension Table Upgrade

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Project by Ick posted 03-11-2018 06:04 PM 2989 views 5 times favorited 6 comments Add to Favorites Watch

I finally decided that I’d gotten about as much life out of my old table saw out feed extension, so I upgraded it. The old one is shown in the last picture (painted green). The issues that prompted me to build a new one:
  1. It had become my primary workbench – due to my shop layout / size, most of the glue-up, assembly happened on the extension table
  2. The top was plywood, supported by a plywood frame. It was getting gouged, and the screws holding it together were not holding up to the pounding that it saw.
  3. The paint was starting to transfer to my projects.
Additionally, I wanted to address some issues:
  1. I wanted a power strip close, so that I could plug multiple portable tools into.
  2. I wanted to be able to mount an old vice that I had.
  3. I wanted a surface / edge that I could readily clamp workpieces to.
The things that worked well with the old extension were:
  1. It’s dimensions allowed me to work safely with the materials that I worked with most of the time.
  2. It was solid, considering the plywood top.
  3. It folded, allowing me to move my saw around.
The basic table has 2 areas:
  1. Fixed Extension – The fixed extension extends from the back from the table saw 16”. This allows for dados to allow the miter gauge to utilize the full length of the table. The extension is supported by the angle iron that supports the back of the fence. The free end is supported by 2 legs that go down to another, lighter angle iron that I’d bolted to the side of the cabinet (for the old extension). The miter slot dados were prone to filling up with sawdust, so I drilled a 3/4” hole at the free end in each slot. The fixed extension is madeup of 1 1/4” thick paint grade maple strips cut from 13/16” material.
  2. Foldable Extension – This extension extends another 30”. My table saw top is 34 1/2” from the floor. This allows for the thickness of the deck. The foldable extension is attached to the fixed extension by a piano hinge. It is also attached to the leg bracket by another piano hinge. The overall deck thickness is 2 1/2”, so that puts the hinge point 2 1/2” below the top of the deck (or at 32”). The foldable extension is made up of both 1 1/4” paint grade maple slats and 2 1/2” paint grade maple slats. I used the 1 1/4 up to a width of ~10” and glue that up; then I could run that block thru my 12” surface planer. In between the 10” blocks, I’d throw in a 2 1/2” slat for extra support. It it wrapped in 2 1/2” and the front has (3) 2 1/2” slats to support the vice and clamping.

I added the vice (existing), and got a router plate. I drilled 3/4” holes periodically for handling bench dogs. I finished it off with some Danish Oil.

-- Craig, Oklahoma

6 comments so far

View MrWolfe's profile


679 posts in 761 days

#1 posted 03-11-2018 07:21 PM

Great upgrade. It seems very multi-functional, especially with the added router insert, dog holes and vise.
And it looks very solid and aesthetically pleasing.

View Joe's profile


525 posts in 1724 days

#2 posted 03-11-2018 09:09 PM

Looks great, nice job!

-- CurleyJoe, "You only learn from your mistakes"

View helluvawreck's profile


32086 posts in 3504 days

#3 posted 03-11-2018 09:15 PM

This turned out nicely.

helluvawreck aka Charles

-- helluvawreck aka Charles,

View Raythefirewoodguy's profile


16 posts in 744 days

#4 posted 03-11-2018 10:36 PM

Well done.
I never know where to start. So I am always impressed when I see someone actually finish a set up like this.

View crowie's profile


3439 posts in 2588 days

#5 posted 03-11-2018 10:43 PM

You’ve done a top job on that table sir, and the extras are great…well done!!

-- Lifes good, Enjoy each new day...... Cheers from "On Top DownUnder" Crowie

View woodbutcherbynight's profile


6058 posts in 3047 days

#6 posted 03-11-2018 11:08 PM

A well planned and thought out project. Excellent work.

-- Live to tell the stories, they sound better that way.

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