The Bench Saw Project II

I am back in the shop and getting this project finished today. The object is to take an inexpensive bench saw and make it more like an expensive, full-sized, table saw by extending the tabletop with an in-feed and out-feed addition. This will allow me to cut longer pieces of stock more accurately and safely.

Once the project is complete, I will post photos which will make the directions make sense. Also, feel free to post questions in comments or e-mail for clarity on any steps.

I started last weekend with a rough drawing with no measurements on it. I decided that the best way to approach this project was on-the-fly and expecting changes as I go.

Last Tuesday, I outlined the beginning of the project and a couple of mistakes I made (Click here to read it).

The side pieces got bolt holes drilled in them to mount to the stock holes that came on the saw. If you have a saw with no holes, they can be drilled (and tapped if you have the means) to mount the frame. Once I got those mounted I measured from the table saw 3" to the front to accommodate the fence and saw guard, and 5" to the rear to accommodate the fence latch. I added the 17-1/2" from the two, 3/4" thick MDF (particleboard) table surfaces to both ends. These were intended to be shelves, but this project has repurposed them.

Now, with the table frame cut to size I cut dado's in the ends of the side pieces to receive the two end pieces. Finally, I will be putting a 1/4" wide groove, 3/4" deep in the frame where the MDF will sit to make it more stable.

Following that, I will rip an 8' 2"x4' length wise to make legs and use the router to cut groves for the miter gauge.

If all goes well, I'll post photos next. If it goes badly, I'll document that too.