Crafting Custom Table Saw Extension Wings: A Comprehensive Guide

Building table saw extension wings can be a great way to customise your table saw and make your woodworking projects more efficient. Most table saws come with an extension wing on the right-hand side, which can be replaced with a router table. This modification is convenient, saves space, and is inexpensive to build. When creating extension wings, it is important to start by finding the right materials and ensuring accurate measurements. The process involves removing the existing wing, constructing a new frame, and carefully bolting the new extension to the saw. This upgrade can enhance your woodworking experience and make cutting and shaping wood easier and more accurate.

Find materials for the extension wings

When it comes to finding materials for your table saw extension wings, there are a few options to consider. The first step is to look for suitable wood. In the example from Jay's Custom Creations, the author was able to source some old boards from a barn loft. Reclaimed wood like this can be a great option, but it's important to note that it may require additional work to clean and mill it before use.

Another important consideration is the surface material for your extension wings. While you could opt for a plain wood surface, using a laminate or Formica countertop can provide a smoother and more durable work area. In the example, the author sourced a free piece of Ebony Granite Formica from a local lumber yard that specialised in custom countertops. This not only provided a sturdy surface but also added a stylish touch to the extension wings.

When choosing materials for your project, it's essential to consider the dimensions and thickness of the wood. For the frame, you'll want to use wood that is thick enough to provide a sturdy base for your extension wings. In the example, the author used oak that was slightly under 6/4 of an inch thick. They also ripped the wood to a width of 2-1/4 inches, which would determine the height of the extension wings.

For the surface of the extension wings, the author chose a piece of Formica laminate. They cut this piece to an approximate width, ensuring that it was squared off at a perpendicular angle. It's important to note that you may not need to cut the laminate to its final length at this stage, as the exact measurements will depend on how you assemble the frame.

In addition to the wood and laminate, you'll also need appropriate hardware to attach the extension wings to your table saw. This may include bolts, screws, washers, and nuts. It's a good idea to check the size of the bolts and sockets required for your particular table saw model before purchasing or sourcing these materials.

Overall, finding the right materials for your table saw extension wings involves a combination of sourcing suitable wood, choosing a durable and aesthetically pleasing surface, and gathering the necessary hardware for assembly. With careful planning and a bit of creativity, you can create functional and long-lasting extension wings for your table saw.

Cut, mill, and plane the wood

Cutting, milling, and planing the wood are crucial steps in building table saw extension wings. Here's a detailed guide:

Cutting the Wood

Before starting the milling process, it's essential to cut the wood to rough length. This helps in two ways: firstly, shorter boards require less material removal during milling, making the process more efficient. Secondly, cutting the wood to a manageable length makes it easier to transport and work with when milling. When cutting, ensure you leave a couple of inches of extra length, which can be trimmed later.

Milling the Wood

Milling is the process of flattening, squaring, and smoothing the wood. Here are some tips for milling:

• Inspect each board before milling: Check the grain direction, cupping, and bowing. Organise the boards accordingly to streamline the milling process.
• Flatten both faces first: Start by jointing one face of the board, then use a planer to plane the second face parallel to the first.
• Joint concave surfaces first: Most boards have one concave side and edge. Orient these surfaces downwards during the initial milling stages for better stability.
• Mill in stages: Instead of rushing to final dimensions, mill in stages. Joint one edge and a face, then let the wood rest for a few days before completing intermediate planing. This allows the wood to stabilise and reduces the risk of warping.
• Use a sled for twisted boards: If you're dealing with twisted boards, use a planing sled to stabilise them during milling. Shim the gaps between the sled and the board to create a flat surface.
• Take light passes: When planing, remove no more than 1/16" with each pass. The final passes should be even lighter, around 1/32" or less.

Planing the Wood

Planing is the process of smoothing the wood and achieving the desired thickness:

• Allow extra wood for planing: Depending on the length and condition of the boards, leave enough extra thickness to account for the material removal during planing.
• Use dust collection: Connect your planer to a dust collection system to prevent shavings from building up and causing pockmarked surfaces.
• Plane both faces: After milling one face, remove the board from the sled and plane the opposite face. Try to remove an equal amount of stock from each face to minimise warping.

Assemble the frame

To assemble the frame for your table saw extension wing, you'll need to follow these steps:

First, carefully measure the distance between your saw's fence rails. This measurement is crucial as it will determine the width of your frame. The frame should fit snugly between the saw rails. In the example provided, the distance between the fence rails was 271/8".

Next, cut the wood to size for the frame. The wood should be solid and sturdy, typically 1x4 lumber is recommended. Take your time with this step to ensure accurate measurements.

Now, it's time to join the frame pieces together. Use butt joints and secure them with 2" screws and wood glue. Make sure the joints are tight and sturdy.

Add a ledge inside the frame to support the top surface. This ledge should be set at a depth equal to the thickness of the bottom plywood layer. This will provide a stable base for the subsequent layers.

Install additional ledges to support the bottom plywood layer. Use a scrap piece of wood as a depth gauge to accurately position these ledges. Ensure everything is level and secure.

Fit the frame into position on the saw. As the middle and top layers will rest on the frame, set the frame slightly lower than the saw surface. Mark the location of the bolt holes for attaching the frame to the saw table. You can use a dab of paint to transfer the hole locations onto the wood frame.

Drill the holes in the frame and elongate them for height adjustment. You may need to use a hole saw for a precise cut. The holes should be slightly larger than the bolts to allow for fine-tuning during installation.

With the frame bolted to the fence rails, check its fit and make any necessary adjustments. Ensure the frame is secure and level with the saw table.

Now, you can move on to installing the bottom plywood layer, followed by the middle and top layers. Measure the inside dimensions of the frame and cut the plywood to fit. The middle and top layers should be cut oversized initially and trimmed down later.

By following these steps, you will have assembled the frame for your table saw extension wing, providing a stable and secure base for the subsequent layers and ensuring a precise fit with your table saw.

Bolt the frame to the saw

To bolt the frame to the saw, you will need to follow a few important steps to ensure a secure fit.

First, you will need to build the frame to the specific dimensions of your saw, taking into account any unique mounting requirements and interferences. Mark the location of the bolt holes on the frame, which should correspond to the holes on the saw table. You may need to use a different size socket for the bolts attaching the frame to the saw compared to the bolts attaching the frame to the rails. Drill the holes in the frame and elongate them to allow for fine-tuning and height adjustments.

Next, fit the frame into position on the saw and mark the location of the bolt holes for attaching the frame to the saw table. You can use a dab of paint around the bolt holes to transfer the location to the frame, ensuring accurate drilling. After drilling the holes, bolt the frame to the fence rails and the saw table to check the fit. Ensure that the bolt holes are large enough to allow for any necessary adjustments.

Finally, make any required adjustments to ensure the frame is level and aligned with the saw table. Ream out the bolt holes in the frame if necessary to achieve a flush and level fit. Once you are satisfied with the alignment, bolt the frame tightly in place on the saw.

Adjust for perfect alignment

Perfect alignment is crucial when installing extension wings on your table saw. Here are some detailed steps to achieve that:

First, ensure the extension wings are flush with the tabletop. Clamp two straight boards, approximately 3 feet long, to one of the cast-iron extension wings, allowing the boards to extend over the main tabletop. This will help you achieve a consistent alignment. Hold the wing in place, aligning it front to back with the table edges, and then clamp it tightly to the main tabletop.

Next, perfect the edge alignment. Use a rubber mallet to gently tap the wing laterally until the mounting holes align. Insert the mounting bolts and hand-tighten them. If you need to make minor height adjustments, use a scrap board on your leg for leverage. You can also use parallel-jaw clamps to micro-adjust the wing height and eliminate any sagging.

Now, focus on the feet for precise levelling. Utilise a long straightedge that spans from the extension table corners to the cast-iron top. Adjust the height of the adjustable feet until the table surface is level. Fine-tune the feet until the two surfaces are perfectly level, then tighten the table-mounting nuts to secure the setup.

If your table saw has an extension table, don't forget to level it with the top. Assemble the extension table, support legs, and frame on the tabletop to avoid unnecessary bending. You can also use clamps to aid in alignment. Clamp directly on the seam between the mating table surfaces or use a board with a straightedge and clamps to ensure a precise fit.

Finally, if your table saw has rip-fence rails, you can align them using a couple of tricks. Use adjustable-height work supports to hold the rail in position while you insert bolts. Alternatively, if you don't have adjustable supports, rest one end of the rail on the floor while loosely securing the other end with a bolt, then repeat for the opposite end.

Frequently asked questions