This project was built by Zach from Bear Mountain Builds.
If you’re looking for a smart way to maximize space in a small workshop, be sure to check out his channel for more woodworking videos.
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A Space-Saving Outfeed Table
An expandable outfeed table is a great solution for those working in small shops or garages.
This design allows the table to extend when needed, providing support for full 4×8 sheets of plywood while remaining compact when not in use.
One of the key benefits of this build is its ability to collapse for easy storage. By folding down, it frees up valuable floor space, making it a practical addition to any workshop.
Zach provides detailed plans that outline materials, measurements, and assembly techniques to help make this project accessible.
Constructing the Frame and Base
Zach starts the build by cutting 2×4 pieces for the frame, ensuring they are square for proper assembly.
He also prepares a sheet of three-quarter-inch plywood for the base and saw platform, carefully notching the corners to fit the legs.
To strengthen the structure, he laminates two pieces together to create horizontal braces.
Using pocket hole joinery, he attaches the cross pieces, making sure everything is clamped securely and remains square during assembly.
Installing the Legs and Casters
Once the frame is assembled, Zach installs the legs using glue and screws to provide stability.
He then attaches spacers for the saw platform, making sure the height is properly adjusted before finalizing the assembly.
For mobility, he mounts four-inch caster wheels to the base, ensuring the table can roll smoothly across a workshop floor.
Using high-quality casters helps prevent issues when moving the table over sawdust or small debris.
Adapting the Table for Different Saws
Zach designed this outfeed table specifically for a DeWalt job site saw, but his plans include formulas to modify the frame for other saw models.
This adaptability makes the build useful for a variety of workshop setups.
To allow the saw’s front rail to slide freely, Zach cuts precise slots into the frame. He uses custom spacers to get an accurate fit, ensuring the saw can move smoothly while remaining stable during use.
Cutting and Finishing the Tabletop
For the outfeed surface, Zach cuts pieces from three-quarter-inch birch veneer plywood.
Aligning the wood grain between the main tabletop and the expandable swing-out sections creates a seamless appearance.
Miter slots are added to the rear surface, allowing for additional customization based on the user’s needs.
Pocket screws are used to secure the pieces in place, ensuring a strong and durable build.
Final Touches and Functionality
The last step is installing folding brackets that lock the extensions in place when needed.
These brackets allow the table to expand for larger projects and fold away when extra space is required.
To enhance durability and reduce friction, Zach applies a protective coat of polyurethane followed by wax. This smooth finish helps materials glide easily across the surface while also giving the table a polished look.
A Practical Upgrade for Any Workshop
This expandable outfeed table significantly improves the functionality of a job site table saw.
It provides extra support for cutting larger materials while remaining easy to store when not in use.
Zach offers detailed plans for this build, making it simple for others to replicate in their own shops.
His design is both practical and adaptable, making it a great addition to any workspace.
Want to see the full build in action? Watch Zach’s video for the complete process and support his channel!