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Folding outfeed table and adjustable legs for my new Sawstop

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Project by Fotodog posted 10-24-2021 01:47 AM 1018 views 3 times favorited 13 comments Add to Favorites Watch

Hello All,
I recently pulled the trigger and got myself a Sawstop Professional saw to replace my 20 year old Jet Super Saw. I’m retiring this year and will be spending more time in the shop, so even though I’m very safety conscious, I wanted the extra layer of protection provided by the Sawstop technology. My first projects have been to customize my saw to fit my needs, particularly since I work out of my garage with a very uneven floor and need to put my saw away each night to make room for the cars.

First was a new crosscut sled. Since there are so many posted here, I won’t bore you with the details except for the method to make the fence completely square. I used the 3 cut technique by Tom McLaughlin, and really like the simplicity compared to the 5 cut method. And most important, it’s dead on accurate. Here’s a link to his video: https://m.youtube.com/watch?v=2l5DFlCRGKo

The next project was an outfeed table. I wanted something very quick and easy to set up, light, but sturdy. I ran across a Youtube video by Colin Knecht and liked his overall concept, so I came up with a design to fit my saw. I made a rectangular frame the same thickness as the width of my saw’s rail, leaving clearance for the door in the back. I really didn’t want to start drilling holes into my new saw, so my design allowed the frame to be fastened to the rail with screws using the existing holes. Next I attached a set of heavy duty shelf brackets from Lee Valley which lock at 90 degrees, and finally attached a sheet of 3/4” black melamine with rounded corners and edge banding applied. It sets up and folds down in seconds.

The Sawstop comes with legs that have a small amount of adjustment, but my floor is so uneven I couldn’t even leave them installed and still roll my saw into position for use. I’ve been using the saw without the legs, but I’m going to install a router lift into the wing and wanted more support. So I built shorter legs with an outer frame from poplar, leaving a center opening slightly larger than the metal legs so they could easily slide inside (after I shortened them). I installed a threaded insert and star knob to tighten the leg in the “up” position when rolling, and then dropping the leg down to floor level instantly once the saw is in position. It works great, very quick and solid.

I hope that some might find this information useful.

-- Tim





13 comments so far

View gdaveg's profile

gdaveg

394 posts in 487 days


#1 posted 10-24-2021 01:59 AM

Tim,

Looks great. You will love the large outfield table.

Will look at the 3 cut method to square.

-- Dave, Vancouver, WA & Tucson, AZ

View BB1's profile

BB1

2554 posts in 2132 days


#2 posted 10-24-2021 02:23 AM

Great setup. Looks classy and having the outfeed support is another way to increase safety. Enjoy!
And thanks for the video link – will add that to my watch list while I do my biking workout :)

View pottz's profile

pottz

21313 posts in 2269 days


#3 posted 10-24-2021 02:27 AM

man sweet setup,and the extra protection is well worth it.

-- working with my hands is a joy,it gives me a sense of fulfillment,somthing so many seek and so few find.-SAM MALOOF.

View Redoak49's profile

Redoak49

5417 posts in 3273 days


#4 posted 10-24-2021 10:43 AM

Excellent work on your new saw. The out feed table is really nice but I like the legs. You should post more info on how you made the legs. I want to build some like those.

View Foghorn's profile

Foghorn

1349 posts in 671 days


#5 posted 10-24-2021 05:44 PM

Well thought out and looks great!

-- Darrel

View therealSteveN's profile

therealSteveN

9230 posts in 1859 days


#6 posted 10-24-2021 05:49 PM

Looking at it I’m seeing the Swiss Army Knife of saw cabinets. Fold it up at night, and return it to a smaller footprint.

-- Think safe, be safe

View Fotodog's profile

Fotodog

91 posts in 1064 days


#7 posted 10-24-2021 06:18 PM

Thanks gentlemen, appreciate the comments.

Redoak, the legs are made by ripping pieces of 3/4” poplar to form a 24” “tube”. I sized the opening by placing the metal leg inside with washers used as spacers while I glued it up. This keeps the fit loose, which is what you want so that the legs drop down easily once installed.

The legs looked a bit too bulky after they were glued up, and since I was using 1/2” threaded inserts for the star knobs, I ripped down each leg so that the thickness of each side was slightly thicker, about 9/16”. I used a roundover bit to soften the edges. I wanted the top of legs to sit tight against the rail using the existing brackets on the Sawstop, which required a bit of chisel work to provide clearance for the hardware used to attach the brackets.

I’ve included a quick diagram to show the leg profile.

-- Tim

View RDan's profile

RDan

198 posts in 3608 days


#8 posted 10-24-2021 10:15 PM

I have to make a extension table for my PCS, I do not want drill holes either. So excellent idea to prevent that issue. I also like the adjustable leg set. I have a similar issue in my basement with uneven floor due to a floor drain. Sawstop’s Leg mount has a bit to be desired. Dan

View Fotodog's profile

Fotodog

91 posts in 1064 days


#9 posted 10-24-2021 11:04 PM

Dan, I agree about the SS legs. Everything else on this saw is first class, these seemed like an afterthought. But if that’s our biggest complaint, I’ll take it. It’s a pleasure to use.

That does remind me of a question for other SS owners; how in the heck do you store the blade guard and riving knife in the provided accessory holder which mounts on the side? I’ve tried every possible orientation I can think of and I can’t get them to fit.

BTW, the cross brace might be overkill, but it really ties the assembly together. You just need to use joinery that doesn’t interfere with the leg sliding inside. I used my trusty Dowelmax.

For those not accustomed to using threaded inserts, they can be difficult to install dead straight. I used the drill press technique where you thread a couple of nuts onto the bolt, then the insert, and chuck it squarely into the unplugged DP. You lower it into the hole and turn the chuck by hand as you apply downward pressure to screw the insert into place. If someone has a technique they like better, particularly for large pieces, I would look to hear it.

-- Tim

View AJ1104's profile

AJ1104

1395 posts in 2944 days


#10 posted 10-25-2021 02:05 AM

Great setup. Nice job designing this outfeed. Enjoy your saw stop!

-- AJ

View NormG's profile

NormG

6574 posts in 4288 days


#11 posted 10-26-2021 12:27 AM

Congradulations on the retirement, outfeed table are so beneficial, especially if they can fold down to conserve limited space. Thank you for sharing your project with us today from Henrico County Virginia

-- Norman - I never never make a mistake, I just change the design.

View mafe's profile

mafe

13404 posts in 4374 days


#12 posted 10-27-2021 08:00 PM

I’ll call that a dream saw.
Would love a saw like that one fine day.
Fine work on the additions, love that you kept the style.
Best thoughts,
Mads

-- MAD F, the fanatical rhykenologist and vintage architect.

View iminmyshop's profile

iminmyshop

395 posts in 3278 days


#13 posted 11-19-2021 03:50 AM

Great job and well thought out. Adjustable legs using your method are now on my to-do list. Thanks!

-- http://www.alansfinewoodworking.com/

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