How to Make a Table Saw Extension

Large sheets of plywood on a small table saw can be very difficult to cut accurately.

A portable table saw has a small table, which makes cutting large sheets of plywood difficult.A portable table saw has a small table, which makes cutting large sheets of plywood difficult.
One solution is to create a table saw extension table that can be put on the side of the table saw, to help support the wide plywood as it's being cut. Make a table saw extension table very inexpensively from common building materials.

Place the four 33-inch-long boards on a flat surface on edge, parallel to one another. Position the two 30-inch-long boards at the ends of the four 33-inch boards, and spread the four boards out so that the outer two boards are flush with the ends of the two 30-inch boards. The two boards in the center should be evenly spaced. Connect all joints with a pair of 2-1/2 inch deck screws using a power drill.

Place the sheet of plywood over the rectangular frame. All four sides of the plywood should be flush with the edges of the frame. Attach the plywood to the frame with four 1-1/2 inch deck screws through the plywood into each framing member.

Measure the distance from the top of the saw table to the floor on which it is standing. Subtract 1/2 inch from the measurement, and cut the remaining four 2-by-4 boards to this length to serve as legs for the extension table.

Flip the table frame upside-down, so that the plywood is below the frame. Stand one of the four legs in the corner of the frame. Use the framing square to verify that the leg is square to the table frame, and attach it to the table frame with three 2-1/2 inch deck screws. Repeat with the other three legs.

Flip the table over onto its legs, and position the table directly to the left of the table saw. In this position, the table will help assist with wide panels.

Things You Will Need

  • 30-by-36-inch sheet of 1/2-inch sanded plywood
  • 2 30-inch lengths of 2-by-2-inch lumber
  • 4 33-inch lengths of 2-by-2-inch lumber
  • 4 36-inch lengths of 2-by-2-inch lumber
  • Power drill with bits and Phillips screw tip
  • 2-1/2 inch deck screws
  • 1-1/2 inch deck screws
  • Tape measure
  • Framing square

Tip

  • You can make the table top any size that you wish, but, since most table saws are either 30 or 36 inches wide, the above dimensions are a good guideline.

Warning

  • When working with power tools, wear appropriate safety equipment, including safety glasses to protect your eyes.

About the Author

Chris Baylor has been writing about various topics, focusing primarily on woodworking, since 2006. You can see his work in publications such as "Consumer's Digest," where he wrote the 2009 Best Buys for Power Tools and the 2013 Best Buys for Pressure Washers.