DWE7491 Table Saw Folding Outfeed Table
Introduction: DWE7491 Table Saw Folding Outfeed Table
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In this woodworking video I'm going to be making a table saw folding outfeed table for my DeWalt DWE7491RS. I have a tiny woodshop that is a 1 car garage and I have limited shop space. So, when I decided I needed an outfeed table, it couldn’t take up any more room in my shop. My only option was a folding outfeed table. This is a space saving solution that will keep your garage organized while improving the workflow in your shop.
I’ll walk you though taking the plan, taking measurements, building the frame, attaching the hinges and attaching the outfeed table top. Then I’ll test it and show you how it works.
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Downloadable plans for the latest version of this outfeed table- https://howidothingsdiy.com/printable-pdf-plans/ol...
Supplies
-3/4" plywood
-(1) 2x4
-Wood screws
-Wood glue
-Folding brackets https://amzn.to/3FM4hQS
Step 1: Creating Mounting Points
Take a good look at the frame of the saw and look for 4 good solid mounting points. It will be different for every saw. I have a DeWalt DWE7491RS and there are two bolts near the bottom that I attached "L" brackets to. Then I drilled two holes in the upper frame to use to screw the new outfeed frame to later.
Step 2: Taking Measurements
Measure any areas that might limit the size of you outfeed table. Ideally it would be great to have a 48" long outfeed table to properly support a 4'x8' sheet of plywood. 493
However, if you plan to fold up the outfeed table, it would hit the ground.
After taking all of these things into consideration, my table was 26" (width of the table saw table) and 24" long.
Step 3: Cutting the Top
After determining the size of your top. Cut the top out of 3/4" plywood.
Step 4: Building the Frame
This step will vary by the saw so I'll walk you though the steps for the DWE7491RS.
First I built a small square frame out of 2x2 that contacts the 4 attachment points.
Then I cut 2x4 pieces to attach the first piece to the folding brackets.
I cut out any areas that needed clearance. Then I attached the 2x4 to the 2x2 square frame with screws and glue. Then I attached the "L" brackets.
Finally, I attached the assembly to the saw with the "L" brackets and the top screws from behind.
NOTE: Be sure to set the saw to max bevel setting to ensure that your frame is wide enough to clear all components when making beveled cuts. You can also cut a notch if that works better for you.
Step 5: Attaching the Brackets
Next I attached the brackets to the frame with screws. The most important thing is to make sure the brackets are positioned so the 3/4" top will be slightly below the table saw top.
Step 6: Attaching the Outfeed Top
Now attach the top to the frame with screws that are shorter than the thickness of the top. When the table is in the up position, make sure both sides of the top are the same distance from the saw top. Also be sure that when the top folds down there is no interference with any other components on the frame or table saw.
Step 7: Roundover, Sanding & Wax
Add final details. I added a 1/8" round over to ensure the boards never get hung up on any edges when making a cut. Then I sanded and applied paste wax for a nice smooth, slippery surface.
Step 8: Test
Finally, make a test cut to ensure the work piece transitions smoothly to the outfeed table. If it does not, you can make minor adjustments by using washers as spacers or drilling new holes in the brackets.
Enjoy saver, easier cuts! 56