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Table saw extension

Table Saw Extension

Have you ever been working with a table saw and realized that there was not enough room to work with? Or maybe, have you ever wanted to rip a wide plank, but the ripping capacity of your table saw was just too low? Well, whatever the case may be, we have the right solution for you, and that comes in the form of a table saw extension.

If you are a handyman who likes to do everything yourself, you might be interested in building your own table saw extension as opposed to buying one. That way you can make a table saw extension just the way you want it, plus you can feel satisfied in knowing that you have built something useful with your own hands. With these simple steps, you can build your own table saw extension that will serve you for years to come.

What Is A Table Saw Extension – The Benefits

A table saw extension is a piece that you can attach to either side of your table saw, or to the front and back too (in which case it is referred to as either an in feed or out feed table). A table saw extension can be either a simple supportive frame (such as the one we help you build below), or it can have a solid table top.

Either way, an extension is a valuable tool for increasing the amount of space you have to work with. It lets you work on wide or long pieces with ease thanks to the extra support that it gives any workpiece on your table saw.

With one of these things, you don’t have to hold up the workpiece where it would otherwise not be supported without an extension, thus increasing the ease, accuracy, and safety of any cutting project that you undertake.

Table saw extension

What You Will Need To Build Your Own Table Saw Extension

There are a few different materials that you will need for the construction of your very own table saw extension. You don’t actually need too many things, and none of them are all that expensive either. Here are the few things you will need to make your own table saw extension.

The Materials

  • 2 x 1-inch square tubes (steel).
  • 1 x ¾ inch square tube (steel).
  • 2 x ¾ inch angled pieces (steel).

The Tools

  • A tape Measure.
  • A ratchet.
  • A wrench.
  • A drill.
  • Various drill bits.
  • A hole saw.
  • A hack saw.
  • A file.
  • A caliper or micrometer.
  • Some nuts and bolts.

Steps To Building Your Table Saw Extension

Building your own table saw extension with the previously mentioned tools and materials is really not that hard. As long as you follow these simple steps, you will have no trouble at all.

Step 1: Measuring & Drilling

  • Take the 2 x angled steel pieces, which are the pieces that will form the length of the base of your extension rail on either side.
    • Make sure that the open edge of the angled pieces is facing outwards as this will make attaching it to your table saw much easier.
    • Drill 1 hole at the center of the width (at one end) of the angled pieces. This will be where you will later use nuts and bolts to attach it to the original saw table.
    • Drill 2 more holes in each of the angled pieces. One of these holes will be in the center of the angled pieces, and the other will be at the far end of the angled pieces. This will form the base of the extension with all of the drilled holes necessary to attach the other metal pieces.
Table saw extension
  • Take the 1 x ¾ inch steel tube. This will form the divider between the base (the angled pieces) and the actual top of your extension, and this is so that the finished extension top has the same height as your original saw table.
    • Cut the ¾ steel tube in half (1 for each rail).
    • Drill 2 holes in each of the ¾ inch steel tube pieces you have just cut in half. The holes need to be at either end of the pieces, and most important, they need to be the same distance apart as the center and outer holes of the angled pieces which you have drilled (as they will be bolted directly to the angled pieces when it’s time for assembly).
table saw extension
  • Take the 2 x 1-inch square steel tubes. These will form the top rails of your extension, or in other words, the surface where your work piece will rest while using the table saw.
    • You will drill 2 holes in each of these pieces, 1 at either end.
    • Measure the distance from the front bottom rail to the back bottom rail (the angled pieces that form the base rails of your extension), or in other words, the depth of your original table saw top. This is where you will drill the holes in the 1-inch steel tubes.
    • Use the pocket drill to make 1 – ¾ inch holes when doing this. This will allow you to use a ratchet to tighten the bolts within the holes (you don’t want the bolts to protrude past the top of the 1-inch tubes because that will create an extension that is not flat on top).
table saw extension
  • After you have drilled all of the holes, make sure to use a file to file away any rough edges and ridges created by the drilling process.
  • how to build table saw extension

Step 2: Assembling The Pieces

Now it is time to assemble all of the pieces into which we have just drilled the holes. This part is very easy because all you need to do is use a wrench or ratchet, and use the bolts and nuts to secure all of the pieces together. Just refer to the picture below if you are having trouble with assembly.

  • First, you need to attach the 2 pieces of ¾ inch steel tube to the far end of each of the 2 angled pieces that form the bottom rail. This will form the rail with the spacing bars on top.
instructions on how to build a table extension
  • Now that you have assembled the bottom rails with the spacers, you need to attach the 2 pieces which will form the top. Use simple nuts and bolts to attach the top pieces to face front to back along the bottom rails (which will protrude from the side of the table).
table saw extension step by step
table saw extension demostration

Step 3: Attaching The Extension To The Table Saw Top

Now that you have built the extension it is time to actually attach it to the table top. This is a very easy step. All you need to do is to use 2 bolts (or depending on your table saw model, screws) to attach the extension to the underside of your table saw. What size of screw or bolt you need to do this will depend on the pre-drilled holes that your table saw comes with. Keep in mind that the rails of the extension will always attach to the original table from the bottom.

table saw extension build guide
table saw extension

DIY Table Saw Extension: Conclusion

A table saw extension wing is a really convenient thing to have. It gives you a lot more room to work with and can greatly increase the ripping capacity of your table saw. You could go buy a ready made extension wing, but that is going to be a lot more expensive than one that you make your own, not to mention much less rewarding too. Keep in mind that the extension table we have helped you build is a very basic one. It will allow you to work on larger pieces, but it is not the most advanced version that you could build.

Click here if you want your own DIY extension that actually has a solid top and can support more weight, or click here for a different model of extension table that you might like more. For some more info on building your own extension wing, you can also check out this video. If you have any questions or concerns about a DIY extension table, feel free to ask us anything, and we will get back to you at the first possible opportunity.

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