Introduction: Outfeed Assembly Table Build for About $50 Dollars

I just finished building a small 12'x16' wood shop in my backyard and one of the first things on my list to getting the shop into working order was to build an outfeed table for my table saw. Since my new wood shop is so small, virtually everything I put in it needs to have multiple uses, and I designed this outfeed table with that in mind. I designed it to stand 35.5" tall so that it sits 1/2" lower than my table saw. The table top is large, durable, and sturdy which makes it perfect as an assembly table. The bottom shelf is also large and sturdy which provides a total of 16 SqFt of storage space.

WATCH THE BUILD VIDEO HERE

Materials and Tools used:

1 - Sheet of 3/4" Plywood

1/2 - Sheet Hardboard

9 - 2x4s

4 - 2x3s

Set of 4 Locking Casters - http://amzn.to/2ja7BuA

Circular Saw - http://amzn.to/2ja7BuA

Miter Saw - http://amzn.to/2ja7BuA

Tape Measure - http://amzn.to/2ja7BuA

Speed Square - http://amzn.to/2ja7BuA

Combination Square - http://amzn.to/2ja7BuA

Cordless Drill - http://amzn.to/2ja7BuA

Cordless Impact Driver - http://amzn.to/2ja7BuA

Countersink Drill Bits - http://amzn.to/2ja7BuA

Clamps - http://amzn.to/2ja7BuA

RZ Dust Mask - http://amzn.to/2ja7BuA

CAMERA EQUIPMENT USED:

Nikon D5500 - http://amzn.to/2cV1qv8

Action Cam - http://amzn.to/2cV1qv8

Microphone - http://amzn.to/2cV1qv8

Shop Tripod - http://amzn.to/2cV1qv8

GorillaPod - http://amzn.to/2cV1qv8

Lighting - http://amzn.to/2cV1qv8

Step 1: Building the Legs

Picture of Building the Legs

The legs for this outfeed table are made from 2x4s glued and screwed in an L configuration. Legs constructed in this fashion are very strong and sturdy. I chose to go with 2x4s in an L configuration instead of 4x4s to conserve valuable space on the bottom shelf.

To make the legs you will need to cut 8 pieces of 2x4 stock to 29 1/8".

I pre-drilled 4 of the pieces before gluing and screwing the legs together.

Apply wood glue to one of the pieces and place it against another piece so that the 2 pieces form an L shape.

Use 3 1/2" screws to attach the 2 pieces together.

Repeat these steps until you finish all 4 legs.

WATCH THE BUILD VIDEO HERE FOR DETAILS

Step 2: Assembling the Frames

Picture of Assembling the Frames

Next step is to assemble the frames for the top and bottom shelves.

Each frame measures 48" x 48"

You will need to cut:

4 pieces of 2x4 stock at 48"

6 pieces of 2x4 stock at 45"

Use glue and screws to assemble the 2 frames as shown in the picture. The 45" pieces will be attached inside the 48" pieces if that makes sense. It must be assembled this way to ensure the frame is a perfect 48" x 48" square.

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Step 3: Attaching the Bottom Shelf and Casters

Picture of Attaching the Bottom Shelf and Casters

Rather than mounting the bottom shelf up a few inches like most other outfeed tables I've seen, I wanted to conserve as much storage space as possible, so I mounted the bottom shelf flush with the bottom of the legs.

Use glue and screws to attach the bottom shelf to the legs.

Align one leg in each corner of the shelf so that they are both flush with each other.

Once you have all 4 legs attached, flip over the whole assembly and attach the 4 casters to the bottom. There is nothing much to this step other than placing the casters on the frame and screwing them down.

WATCH THE BUILD VIDEO FOR DETAILS

Step 4: Attaching the Top Shelf

Picture of Attaching the Top Shelf

Attaching the top shelf is no different than the bottom shelf, using wood glue and screws.

The only difference with the top shelf is that it isn't attached flush with the legs.

When attaching the top shelf, make sure to attach it so that the top of the legs are 1 5/8" below the top of the shelf.

This allows enough room to trim the entire top portion of the outfeed table with the 2x3 stock once you attach the plywood and hardboard.

WATCH THE BUILD VIDEO FOR DETAILS

Step 5: Attaching the Plywood

Picture of Attaching the Plywood

I designed this outfeed table to require only 1 sheet of plywood. One of the things I hate the most is having to buy 2 sheets of plywood just because you need a tad bit more than a full sheet.

I kept it easy and simple with this one.

All you have to do is cut the sheet of plywood exactly in half and you have your material for both shelves.

Place the plywood on top of the frames and attach them using screws (I used 2 1/2" screws).

WATCH THE BUILD VIDEO FOR DETAILS

Step 6: Adding the Hardboard Top

Picture of Adding the Hardboard Top

Only a few more steps to go.

I wanted to cover the top of the outfeed table with hardboard for a few reasons, first because it is smooth, and second because it is durable.

You can chose to cover both the top and the bottom with hardboard if you want, but since I am storing tools underneath, I chose not to.

Cut the hardboard sheet in half so that you get a 48" x 48" square.

Apply a generous amount of wood glue to the surface of the plywood and spread it out evenly with a scrap piece of wood or a spatula.

Place the hardboard on top of the plywood and glue and place as much heavy objects on top that you can find to weigh it down until the glue dries.

WATCH THE BUILD VIDEO FOR DETAILS

Step 7: Finishing Up With Some Trim

Picture of Finishing Up With Some Trim

This baby is almost done!

All that is left is to add the trim to the top and it is ready to use and abuse.

You will need to cut the following pieces out of 2x3 stock.

2 - 51"

2 - 48"

Make sure that the top of the trim is flush with the top of the table and attach the trim using screws(I used 2 1/2" screws).

The trim will protect the plywood and hardboard sides from damage and also increases the work surface from 48" x 48" to 51" x 51".

WATCH THE BUILD VIDEO FOR DETAILS

I hope you enjoyed this project.

Feel free to follow my instructables profile. And my last request is that you check out our YouTube channel and subscribe if you enjoy the content.
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Comments

mattbaca (author)2017-01-10

What design software is that. The 3d model pictures

I use Sketchup for all my 3D modeling of projects. It used be called Google Sketchup but I think they sold it. It is a free software and you can download it just by searching sketchup in google.

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Bio: I am a Building Automation Engineer at a major University in California. My favorite people in the world are my wife Bouavon, and my two ... More »
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