Shop built Sliding table for Tablesaw #6: Building the Outrigger

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Blog entry by Todd Swartwood posted 11-29-2014 12:15 AM 7378 reads 2 times favorited 6 comments Add to Favorites Watch
« Part 5: Adding the table to the BT's Part 6 of Shop built Sliding table for Tablesaw series no next part

I started with a scrap of 1/2 MDF big enough to get both sides of the outrigger. I believe the measurements were 48” long, 16” high at the end next to the saw, and 12” high at the outer end.

This picture shows how I laid it out:

I began by ripping down a Douglas fir 2×12 into strips about 2 3/8” wide. I used this for my framing around the edges.
I left the small end open and laid the 40 X 80 mm extrusion in the center parallel to the side that was cut square. I then laid out 6 sets of bearings, 3 for each side of the extrusion. I laid the bearing out so there was one set at the top and bottom of the extrusion near the narrow end of the outrigger. I laid another set top and bottom top and bottom at the other end of the extrusion in the furthest open position. I then laid out one more set In between the other 2 sets.
I marked all of the bearing positions with a 5/16” transfer punch. I then laid front and back on top of each other so I could drill both at the same time. I then put a bolt with washer under heads for all 6 locations. I then added 2 washers
to each bolt on the inside to space the first bearings off the MDF. Then added the bearing and another washer on top of the washers. Then I cut 3/8” tubing for spacers for all 6 locations, put those in place with another washer on top the spacer. Last I added the second bearing to each location along with 2 more washers to keep the bearing from binding on the MDF. I then laid a 1” rod to the end next to the saw for the unit to swing on. I then glued and screwed the framing around the edges. I also ripped some 1” oak to 2 3/8” to frame around the rod, again gluing and screwing in place. I then had to make 2 spacers to hold the 1” rod centered. I was then able to lay the other side on top of the outrigger. I used a washer and nut at each bearing location, and screwed the MDF in place with no glue. This was done for access for maintenance.
Next I needed to make a clamp for the support end of the outrigger.

As you can see in the last picture the clamp at outer end was 2 pieces of 1/2” ply bolted with 5/16 carriage bolts slid into the T slot. I then cut a piece of 8/4 hard maple and planed to same thickness as the 40 mm thickness of the extrusion. I then drilled a hole down through the maple to hold the outrigger rod. After drilling the hole I split the piece at center line of the hole on the bandsaw. I did not cut all the way through yet leaving enough wood to act as a hinge. I slid the rod through the hole and then bolted the entire piece between the plywood supports. I the drilled 4 hole 2 in front and 2 behind the rod. I then put bolts washers and nuts in each hole and snugged them up.
I then cut off the last inch or so to cut away the wood making up the hinge. The end piece then worked like a clamp to hold the rod at the desired height.

These pictures are of it all done except for paint:

As you can see I can almost rip a sheet of plywood on the slider:

I may do one more of this series finishing it up and painting it thanks for your interest and comments.


-- Todd Swartwood (Todd Swart-Woodworks)

6 comments so far

View Gassit's profile


37 posts in 2719 days

#1 posted 11-29-2014 01:15 AM

How accurate is it doing a 3-foot cut?

View JoeinGa's profile


7741 posts in 2489 days

#2 posted 11-29-2014 02:00 AM

Pretty cool Todd.
I like it and it sure would come in handy cutting up large panels.
I didn’t realize just how much real estate it was going to take up. That would be way too much floor-space to give up in my shop.

-- Perform A Random Act Of Kindness Today ... Pay It Forward

View rodk1's profile


15 posts in 3640 days

#3 posted 11-29-2014 03:22 AM

This is a very, very impressive project. Thank You so much for posting.

View TheFridge's profile


10859 posts in 1968 days

#4 posted 11-29-2014 05:21 AM

Send it to if you fell up to it. A lot of homemade tool builders would appreciate it.

-- Shooting down the walls of heartache. Bang bang. I am. The warrior.

View Todd Swartwood's profile

Todd Swartwood

258 posts in 2207 days

#5 posted 11-29-2014 01:42 PM

My first test cut was a 49” cut and it was not off 1/64”, I sure was smile-in.

Joe, the neat thing is the out rigger come off in less than a minute.

rodk1, I am like a proud daddy of a new baby, I am very happy to let anyone that wants to see it.

I don’t think Matthias Wandel cares much for me.

-- Todd Swartwood (Todd Swart-Woodworks)

View Gassit's profile


37 posts in 2719 days

#6 posted 11-29-2014 07:46 PM

That’s the sort of accuracy I was looking for- well done!

When I sell our house next week, I’ll make your sliding saw and build our next house with it. Thanks!

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