This is my small table saw and cart for which I built an outfeed table.
Step 1: OLD-SCHOOL PLANS
Being an old-timer I sill draw plans by hand on graph paper. You know the adage: Measure twice, cut once? Well, good thing I remembered to do that. The rollers are actually 2 1/2" high, not two. Whew!
Step 2: I CUT THE 2 X 4S TO LENGTH
I double checked to make sure they were all the same length by butting them up to a speed square.
Step 3: I BUILT TWO FRAMES
Here's a tip: when marking out studs 16" on center, gang the studs together, measure 15 1/4", 31 1/4", 47 1/4" etc. and draw a line across both studs (this is how they build walls with top and bottom studs. Then mark an X on the side of the line the stud will be going. Line the studs up with the marks and they will be 16" on center.
Step 4: I SECURED THE TOP TO THE FRAME
I calculated the position of the flattest of the two frames (yes, wood warps) and secured the top. To center the top I positioned the frame against an edge and took half of the overhang on both sides and drew lines.
Step 5: I ATTACHED THE LEGS
Using the top as an assembly table I secured the legs to the other frame, flipped it and secured it to the top frame. Then it was just a matter of screwing on the casters.
Step 6: THE TEST
I rolled my small table saw cart over and tested the height of the outfeed table. It was a perfect fit. This turned out to be a really nice table, and the largest in my small shop. I'll probably use it primarily as an assembly table; and the fact all my carts are on casters makes working in a cramped space quite pleasant.
Step 7: PROLOGUE
This is the last cart I need in my little corner of the world. I hope you gleaned something from this Instructable. And as usual, comments are always welcome and questions are always answered.