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.
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
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.
Step 2: 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.
Step 3: 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.
Step 4: 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.
Step 5: 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).
Step 6: 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.
Step 7: 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".
I hope you enjoyed this project.
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