How to Build a Table Extension for a Table Saw

Table saws can be the most productive tools in a wood working shop. The stationary saw is capable of ripping full sheet plywood down to the smallest trim and molding pieces. One of the problems with the table saw is that table itself is usually too small. Using a basic construction technique of typical wall framing, you can build an extension for that table saw in a matter of a few hours.

Difficulty: Moderately Challenging

Instructions

Things You'll Need:

• Tape measure
• Pencil
• Circular saw
• Two 2-by-4s, 8 feet long
• Seven 2-by-4s, 45 inches long
• Four 36-inch to 40-inch 2-by-4s
• 3-inch Phillips head screws
• One 4 foot by 8-foot 3/4-inch plywood
• Powered screwdriver with Phillips head bit
• 1 1/2-inch Philips head screws

1. Using the tape measure and circular saw, cut the above parts list for the 2-by-4 lumber. You can hold back on the four 36-inch to 40-inch 2-by-4s until the frame legs can be measured for the proper height from the floor to the bottom of the frame. These four support legs will vary in height because of the differences in all table saw heights.

2. Construct the main frame for the extension table by laying out the two 8-foot 2-by-4s to accept the 45-inch-long frame pieces. The frame will be constructed like a mini stud wall, with the 45-inch pieces laid on 16-inch centers. Begin at one end of the longer boards and mark the top edge of the 8-foot 2-by-4s with the pencil for a 16-inch layout.

3. Secure the frame together with the 3-inch-long Phillips screws. Two screws per joint should be used in the construction of the frame.

4. Measure the height of the table saw table from the floor to the top of the metal surface. From this measurement, deduct 13/16 inches. Cut the four table leg supports to this height with the circular saw.

5. Attach the legs to the four inside corners of the 2-by-4 table frame with the 3-inch screws. Use three to four screws to securely affix the table legs squarely to the frame. Assemble the table upside down so the top of the table and legs will rest against or on top of the floor.

6. Flip the new extension frame over onto the legs and lay the 3/4-inch plywood on top.

7. Using the 1 1/2-inch Phillips head screws, begin in one corner and attach the plywood to the frame with one screw. Go to the next corner and align the plywood edges with the frame. Attach again with only one screw. Perform this same process to the remaining two corners. The frame should now be square with the plywood.

8. Finish securing the plywood to the frame by installing the 1 1/2-inch screws every 8 to 10 inches on center into the 2-by-4 frame.

9. Slide the new extension table into place at the end of the table saw. The top of the extension table should be 1/16 inch below the table saw. This will allow for no interference when pushing material through the saw and resting on the new extension table.

Tips & Warnings

• You can build another 4-foot-wide by 8-foot-long extension for a wider-style table. These extension tables can also be moved around the shop as they are not permanently attached to the table saw.