Butt-joint the frame pieces using 2″ screws and yellow glue. The width is critical the frame should fit snugly between the saw rails. So build the frame first that way you can deal with unique mounting require- ments and interferences from the get-go.īuild the frame from 1×4 solid wood to the dimensions determined in the previous step. Building the Frameīolting your completed extension to the saw can be the trickiest part of the proj- ect. Measure the distance between your saw’s fence rails first before cutting any of the project parts to size. If you want an even deeper table, you can extend a bit farther, but no more than about 6″ past the end of the rails. I chose mine to extend to the end of the fence rails, which on my saw is 161⁄2″. The most critical dimension is the width - the distance between saw fence rails mine was 271⁄8″.The depth of the extension is somewhat arbitrary. Remove the extension wing of your saw and determine the size of your new router table extension. NOTE: The dimensions in this Material List may need to be adjusted to fit your table saw. There’s no special fence with vacuum openings and no hoses on the table. The table is made in three layers: a top surface of durable countertop laminate, a middle layer of 1/4″ MDF and a bottom layer that includes the dust conveying chamber, made of 3/4″ birch plywood. Dust and chips are vacuumed away down the bit opening as soon as they are cut. An internal chamber connects the router bit opening on the top surface with a shop vacuum connection on the bottom. The concept I came up with is a dust collection system built right into the tabletop itself. I also wanted effective dust control, but none of the commercially available dust control systems appealed to me. When I decided to add a table-mounted router to my small shop, adding it as an extension to my saw was my best option. It is convenient, saves valuable floor space, and it’s inexpensive to build.
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Replacing this wing with a router table is an excellent modification to your saw. Most table saws come with an extension wing on the right-hand side of the saw table. It features a unique internal dust collection system for cleaner operation. Customize your table saw by replacing one wing with this convenient and floor-saving router table.