Table Saw Extension

A table saw extension will allow you to work more efficiently and also give you more room for working with your table saw.  For those who are inclined to save a few dollars (and who isn’t these days?)the follow will allow you to build your own table saw extension that will allow you to rip panels as big as four-by-eight.

Before building your table saw extension, you will need the following materials and supplies:

• Seven 1 x4 x8’s
• Two 2 x 4 x8’s
• Eight bolts with washers and thumb screws (3/16 x 2 ½”)
• Forty 2” drywall or wood screws
• One adjustable clamp, 4’ straight edge

Cutting the Frame Pieces for Your Table Saw Extension

When building your table saw extension, your first step will be to cut the frame pieces that you will need.  Using one of the 1x4’s, measure and cut four 22” pieces for the ends of your table saw extension.  In the same way, you will next cut one of the 2x4’s into four 22” pieces to form the cross pieces of your table saw extension.  Next, using another 1x4, you will cut four 23 ½” pieces to make the cross piece supports.  The final pieces that you will cut are two pieces of equal length to form the two support legs for your table saw extension.  Measure the distance from the floor to the top edge of your table saw and cut two equal pieces from one of your 2x4 pieces of stock.

Assembling Your Table Saw Extension

• To begin assembling your table saw extension, lay two 1x4’s flat on the floor, and lay your pre-cut 1x4x22” pieces on their edges, one at either end.  Screw these together, using a speed square to make sure they are squared with your design.
• Lay your two 2x4x22” cross pieces on their edge an equal distance from each end. Fasten into place with screws.
• Next, center your 1x4x23 ½” cross pieces across your 2x4’s and screw them into place.
• Center one 2x4 support leg perpendicularly on the outside edge of your table saw extension.  Drill a 3/16” hole.  Connect the leg to the extension with a screw and wing nut.
• Flip over the table saw extension.
• Using plain paper, draw a template of the three holes on the side of your table saw.
• On the top part of the table saw extension that will actually touch your table saw top, use the template you have drawn on paper to drill the three holes that complement the three holes in your table saw. Use a 3/16” drill bit.
• Repeat these steps to complete the second extension.
• Lift both table saw extensions into position.
• Tighten the support legs.
• Attach the table saw extension to the saw using 3/16” bolts, wing nuts, and washer.
• Clamp the 4’ straight edge clamp into the position that you desire on your 2x4’ cross pieces to form a fence to rip your bigger sheets.

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