Today I’m building an outfeed table for my table saw.
I began the project in Sketchup to get a good idea of how it would be put together and what materials I would need. The entire table is built using only 2×4’s’ and a couple sheets of plywood.
I set up a stop block at the miter saw with a scrap board and a quick clamp and cut all the 2×4’s down to the measurements in the plans.
Being able to repeat the exact length on multiple boards is important to make sure the table doesn’t come out crooked.
I amassed a pile of 2×4’s before laying them out.
I brought the boards over piece by piece and mocked up the entire table top structure. I designed the structure like this to be able to incorporate some cool future projects. I used some 3-inch deck screws to lock everything in place. It was really important for me to keep checking my plans to make sure I didn’t put anything in the wrong place.
Here is the finished top structure.
I laid out the bottom shelf in the same way I did the top. This nice thing is that the shelf is much less complicated. I squared everything up and used the same screws to lock the boards in place.
I also added some cross members in the middle for strength. I used a zig-zag pattern to be able to screw them all in from the side.
Now that both top and bottom were complete I could add the legs.I flipped the top upside-down on the floor and screwed the legs in the four corners making sure to keep them square.
I flipped the top over again to now sit on the legs.
I brought the shelf over and placed it underneath the top.
I used a few scraps of 2×4 to hold the shelf evenly off the ground so I could screw it in place.
I moved the completed structure over to its final spot by the table saw.
Although the table is straight, my garage floor slopes quite a bit over the 62-inch span.
I unscrewed the top on the back edge and slowly lowered it until it was perfectly level.
I checked the other side and had to lower the top there as well.
I used the jig-saw to remove the extra board and then cleaned it up with a hand plane, then did the same on the other side.
I brought over the first sheet of ¾ inch plywood. This would serve as part of the top. I had carefully designed how to cover both surfaces with only 2 sheets of plywood so I had to stick closely to the plans. Several times I almost cut the boards in the wrong direction.
I kept measuring, marking, and cutting up the plywood into the correct sized pieces. My table saw only cuts up to 32 inches, so anything wider than that I used the cordless circular saw to get the job done.
I used a bit with a counter sink on it to pre-drill the holes. Then I attached the top using inch and a quarter screws.
I cut the top a little over-sized so I could flush trim it with the router. I set the bit to the correct height and moved around the entire top. Then I went over the top again with a chamfer bit.
The plywood for the base needed to be notched out for the legs. I marked the notches and cut them out using the jig saw, and then cleaned up the edges with some sand paper.
I used the table saw to rip the last few pieces to width, and then cut them to length using the circular saw.
Before routing the edges and screwing them down, I tacked the plywood in place with the brad nailer.
The table was almost done.
The final step was to cut out the slots for any table saw jigs. I brought a jig over and marked out the slots.
Using the router and a large speed square, I carefully free-handed the cuts, going deeper with each pass.
Success. The table was now complete.