SawStop Outfeed Extension

Finally got my upgraded 3HP SawStop setup and it was a great opportunity to add the must-have outfeed table extension.

Because I use the exterior garage door as the typical resting place behind my saw, I wanted to have enough of an extension for those typically shorter pieces. For the longer rips, I wanted the depth, but it had to get out of the way for keeping my usable garage space as efficient as possible. Since I’m in Texas, I get the benefit of opening the garage door 90% of the year, so a two-piece outfeed table made a lot of sense. Having a flip up outfeed table was a great combination when I need to open the door for the extra space and the flip up second half of the outfeed table added the extra support when needed (no more roller stands!).

Using Ted’s write up at http://woodplans.com/projects/43954, I got a head start. Because the 3HP SawStop is a full cabinet saw, I had the nice rigid backing to mount the support brackets for the first fixed section. I used these same “L” brackets for the pivot point that holds the secondary extension support piece.

The results was a deliberately svelte design that minimized the outfeed table bulk. I even used a foam core for the second (flip down) extension to reduce the weight. Since it didn’t need the miter gauge grooves, I was able to sandwich a foam core between two ¼” plywood pieces and then laminate the top and edges with maple. This makes the flip up a lightweight, one handed operation and kept the load down for easily moving the saw around on its mobile base.

The extension support comes from cutting a single piece of plywood in two and joining them with a hinge. The “folding” up in to the back of the saw keeps it out of the way and it auto-locks in the perfect support position when you flip the extension up for use without futzing with any adjustments – perfect every time. A quick, light tuck to the center of the support at the hinge allows it to fold down.

Details:
– Total extra outfeed: 13.5” + 13.5” = 27”
– Piano hinges used for the joints between the two extensions and at the pivot creating the support.
– Fixed extension section attached to the edge of the saw – Glued up two ¾” thick pieces of plywood, laminated on both sides. I router cut the miter slot grooves after mounted it in position.
– Second section – ¼” plywood on top/bottom of a ¾” core made of dense, rigid foam insulation board. The two ¼” pieces were slightly oversized to fit into ¼” grooves in the edging for rigidity.
– Edging – all ¾” maple with rabbited corner joints.
– Fixed Section Support Brackets – Used ¾” aluminum notched at each end to allow for bending an angle to enable mounting to the saw back and to the bottom of the fixed section of the outfeed table. I used threaded inserts for the bottom of the table for some adjustability via a slightly oversized whole drilled in the angle aluminum supports.
– Secondary Support – Pivots half way along its length. I used the lower part of the angle aluminum support to drill a pivot hole. I used threaded inserts in the sides of the lower part for the pivot bolts and small spacers to take up the space I created to allow for pivot-up clearance when you fold down the table (because the support piece folds up in between the two aluminum supports).

Slick, simple and very easy to use. With the secondary section folded down, the 13.5” of extra outfeed table is perfect for most situations and it doesn’t take up any more room than the clearance already required for the dust collector connection hose. It fits nice and close to the closed garage door. When I need the extra room, I either move the saw into the room or simply open the garage door.

Woodworking Projects at LumberJocks.com


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