Introduction: Outfeed Table for Dewalt Table Saw for $10 (includes Plans)

Picture of Outfeed Table for Dewalt Table Saw for $10 (includes Plans)

The most popular table saw on Amazon (as of June 15) is the Dewalt DW series. It's a compact, great contractors table saw. But it really needs an outfeed table to catch the cut lumber.

I wanted an outfeed table which:

  • attached to the table
  • was really easy to put on and take off
  • folded down flat for simple storage when not needed.
  • was very inexpensive.
  • I didn't want to have to get expensive metal parts.

I saw a lot of different plans for out-feed tables that were solid cabinets, but they were too large for me.

Materials:

- one sheet of 24" x 48" ply 1/2" thick. This is a typical size and cost me $10 at my local Ace Hardware. Must be 1/2" thick!

- wood glue for sandwiching wood strips together

- Some 1" wood screws to attach the wooden hooks to the sides.

- 2x 2.5" bolts to "loose secure" the table top to the sides.

You will need:

- a bandsaw or jigsaw for the rounded cuts (mandatory)

- a table saw for the rip and cross cuts (mandatory)

- a few clamps to join the pieces together (mandatory)

- a chisel (optional)

- a router to make channels along the top for a cross cut sled to come out of the miter tracks and onto the table (optional).

The plans:

You can download the PDF plans for this table saw here: Dewalt Table Saw Outfeed Table Plans Included is the sourcefile in Google Sketchup format if you want to alter the plans.

Here is a video of how it will look when you're done: Video, and here is the video of how to assemble it.

Step 1: Cut the Pieces

Picture of Cut the Pieces

The first step is to download the plans and print out the two colored plans. It includes all dimensions for the three main parts. The two sides and table top should be able to all be cut from one 24 x 48" piece of 1/2" ply if you don't make any mistakes.

Start by making the outside cuts.

The green pieces are to mount underneath the table top. Cut them out

The yellow pieces will form the top hook. You will first glue them together and then glue them on to the side.

The purple pieces will form the bottom hook. You will first glue them together, cut the hook, and then glue them on to the side.

On the main side there is a groove at the top which is 1" wide by 1/2" deep. I cut this with a handsaw and a chisel. You could cut it with a jigsaw and chisel. Also on the main side is a big swinging arc. I cut the arc on a bandsaw, but you could also use a jigsaw. The shape of the arc does not need to be very accurate, but you do need to use the waste wood for the purple and green pieces.

Do NOT yet cut the hook in the main side. You will cut the hook once the outer wood is glued on.

Step 2: Glue the Pieces

Picture of Glue the Pieces

Here you can see the side piece all cut out (without the hook yet cut).

Now you need to glue the 2 yellow pieces together. Separately glue the 3 pink pieces together. Side by side.

Try to line them up neatly.

To glue them, cover either side with glue. I use an old credit card to spread the glue neatly.

Then clamp it down really tight and use a wet cloth to swipe off the wet glue that oozes out. Leave it for at least 24 to dry, preferably 48 hours.

Step 3: Cut and Attach the Hooks

Picture of Cut and Attach the Hooks

Do the top hook

Now draw the hook on the top of each side. Draw the hook shape in pencil onto the outside face of each side.

Now take the two yellow piece block which you glued together previously and glue that to the inside face of each side, lining it up to the top. These will form the hook which attaches to the top black bar of the Dewalt table saw. The hook will be 1.5" wide when completed and will provide a nice stable hook which shouldn't flop around. Glue them on, clamp them again like in the previous step and leave it to dry 24-48 hours before cutting the top hook.

Once the glue has dried you can put it into your band saw and cut the shape of the hook (or jigsaw). The bar you're hanging it on is exactly 1" wide, so cut it carefully and ensure it sits snugly and firmly onto the bar sitting flush down at the top of the hook.

TAKE NOTE: the height from the inside top of the hook to the upper edge that the table will sit on must be 2 13/16". See the the plan. This ensures that the table top will sit exactly 1/8" lower than the table saw top. You need the outfeed table top to be slightly lower than the table saw top so that your lumber will slide off the table saw and drop down slightly onto your outfeed table.

The bottom hook

The bottom hook fits against the vertical black bar on the back side of the table saw. This black bar is also exactly 1". So you've got a 1.5" wide block. Cut the 1" hook into this per the pictures with your jigsaw or bandsaw.

This bottom hook will be attached to the side such that the table top sits level. To do this, grab a level, and rest it on top of your side. With a clamp loosely holding the bottom hook onto the side you can adjust it so that the bottom hook rests on the black bar while the top is perfectly level. Once you've found the right spot, clamp it tight and then drill a few wood screws through the side and into your hook. Be sure to predrill the holes so you don't split the hook.

The sides with hooks are complete.

Step 4: Assemble the Top

Picture of Assemble the Top

The top

I made my top 24" wide x 30" long. This means I can push stock <60" (5') long onto the table before it topples off the back. The table is pretty solid but wouldn't hold a LOT of weight before toppling the entire table saw over with leverage. Use your judgement.

Mount the two sides on the table saw.

Rest the top onto the two sides.

Get under neath and mark where the rails need to sit. Then flip it over and screw the rails onto the top.

I drilled holes and put two long bolts through the rails and sides to ensure that the top stays on the sides and doesn't flip up if a heavy piece of lumber is hanging off the back of the table.

Once you've attached the rails, you're mostly done.

As you can see I routed two long grooves into the top of the table so that my cross cut sled can slide out of the miter tracks and onto my outfeed table without being obstructed.

You're done. Here is a final video of my outfeed table in action:

Comments

pcollins12 (author)2017-09-11

Plans moved. Can be found here: https://www.dropbox.com/s/k72s6fkc95exxwo/Dewalt%20Plans.zip?dl=0

jlehm005 made it! (author)2017-02-01

Love this, only have a small garage shop, so when I am not working on projects our car/truck/HD are parked in it. So to have the maneuverability is awesome. I have a different Dewalt - DW7491RS but I found an individual on Amazon that already did the home work on the mods (included a picture).

Ruffle (author)jlehm0052017-04-25

Thanks for sharing your version for the DW7491RS.

Can you still store the riving knife blade guard inside the frame while the outfeed table is attached?

If so, can you post a pic with both of them attached?

jlehm005 made it! (author)Ruffle2017-04-25

Hope this works

jlehm005 (author)jlehm0052017-02-01

Found the written instructions:

The DW7491RS is slightly larger and the vertical tubes are 1.125" not 1 inch which requires laminating 3 pieces together and cutting a 1.125" slot to fit around the larger tube. Horizontal is still 1 inch. Also the distance from the top of the top of the saw table to the top of the horizontal tube is 4.25". To position on the outfeed supports means you must subtract the .125" clearance and .5" ply top. This results in the top of the wood hook needs to be positioned 3.625" from the 1/2" plywood outfeed supports. Bottom line is will work but requires adding one more vertical piece (3 not 2) and sizing it to 1.125" then locating the hook that hangs over the 1" horizontal tube requires locating the top of the hook at 3.625".

pcollins12 (author)jlehm0052017-02-01

Fantastic, please add a photo!

jlehm005 made it! (author)pcollins122017-04-25

Is this what you are looking for?

pcollins12 (author)jlehm0052017-02-01

wow, they look really impressive. I love that he took the time to paint them yellow too! :)

dazza_bo (author)2017-02-17

I'm a little confused about where the bolts go and what their function is. Could someone who has made this table please post a photo of the section with the bolts?

pcollins12 (author)dazza_bo2017-02-22

Here is a video of how to install it including the use of the bolts to hold the top on. https://youtu.be/cPDH81JMS5w

dazza_bo (author)pcollins122017-02-22

Thanks mate, really appreciate that. Makes perfect sense now. I've got most of the pieces cut now I just gotta assemble it all!

JayeMoney (author)2017-01-29

I spent part of my weekend trying to figure out how to make a stand for my DeWalt to let me use an existing table as an outfeed. I was annoyed, as the table was lower than I would have preferred and as I was looking for ways to figure out how to raise the table and make both my saw and my outfeed less stable than usual I came across your plans.

One evening later I'm done, it looks great, works like a charm, and I feel safer already. Many thanks for these, I think it's great for my use.

pcollins12 (author)JayeMoney2017-01-29

So glad that the plan is getting repeat use. I still use mine regularly.

JörgenBörg (author)2017-01-05

nice one!

YumanBeing made it! (author)2016-05-06

Just what I was looking for. Saw is a DeWalt DWE7480 and this fit perfectly using your measurements. Don't have a bandsaw and didn't want to attempt the 1/2" radius cuts with a jigsaw so I chucked a 1" forstener bit in the drill press, punched side by side holes and used the jigsaw to clean up what was left. Came out nice. I also decided to make it more of a permanent 1-piece table and poked a 3/4" hole so I could hang it from the ceiling, out of the way. Thanks for the great instructable!

pcollins12 (author)YumanBeing2016-05-08

Awesome to see. Glad it worked!

semifrank (author)2016-01-17

Wasted 10$ and a few hours on this.

Dude, your diagram shows the measurement from the inside off the hook to be 3" 5/16. I used the diagram to measure and cut all of the pieces. When I put the pieces onto the saw, something was clearly wrong. Went back and read the instructions and found this: "TAKE NOTE: the height from the inside top of the hook to the upper edge that the table will sit on must be 2 13/16"" - This is NOT consistent with your diagram at all. Bummed.

pcollins12 (author)semifrank2016-01-17

Hmmm... the diagram looks consistent what what I built (my "note" comment used the wrong number). How has it turned out incorrect? Is the top of the table sittting too low?

semifrank (author)pcollins122016-01-17

as is, the top of the frame piece is flush with the saw's table, so with another 1/2" on top of it, it will be too high, and I don't have any real good way to trim the long edge of that piece without F'ing it up.

eddevine (author)2015-06-28

This may be just what I was looking for, just had a minor mishap kickback hitting my hand and getting a few stitches. Can't wait to try your design, thank you for posting

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