Author Topic: Quick Compact Outfeed Table for DeWalt Portable Saw  (Read 5779 times)

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Offline Dick Mahany

  • Posts: 551
Quick Compact Outfeed Table for DeWalt Portable Saw
« on: July 26, 2018, 06:20 PM »
Here is a quick assembly, compact outfeed table for a DeWalt jobsite saw.  I took inspiration from a few others that I came across on the internet and built mine to store in a small space and simply lift on and off the saw.  One of the challenges is how to mount it due to the rear track for the rack and pinion fence.  It is actually quite simple, however since it mounts on and off a welded tube assembly, I built this one in place on the saw as I wanted to assure the extension was parallel to the saw table. 

The sides are made from 15mm Baltic Birch and the top is made from awful home center nominal 3/4" birch face ply.  I also used a trick I learned from David Stanton's videos and that was to sand the top to 220 grit and then use paste wax and power buff with a ROS and steel wool.  Slick surface and easy to maintain.

Another FOG member asked about it so here it is......



I can assemble this more than one way, hence the orientation arrows below   haha.










The rear clearance is just enough to allow the rear fence mount to slide without contacting the outfeed table.  This gap has never been a problem in practice.


I had to use something Festool for this project  [big grin]




« Last Edit: July 27, 2018, 09:00 PM by Dick Mahany »

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Offline HarveyWildes

  • Posts: 928
Re: Quick Compact Outfeed Table for DeWalt Portable Saw
« Reply #1 on: July 26, 2018, 08:52 PM »
Nicely done.

Offline neilc

  • Posts: 2834
Re: Quick Compact Outfeed Table for DeWalt Portable Saw
« Reply #2 on: July 26, 2018, 09:00 PM »
That's nice - My son and son-in-law have that saw and I have one on my farm.  They are really nice saws in a compact footprint.

Can you share the dimensions of the extension wing?  Might have to make one, two, or three!

Offline Dick Mahany

  • Posts: 551
Re: Quick Compact Outfeed Table for DeWalt Portable Saw
« Reply #3 on: July 26, 2018, 09:21 PM »
That's nice - My son and son-in-law have that saw and I have one on my farm.  They are really nice saws in a compact footprint.

Can you share the dimensions of the extension wing?  Might have to make one, two, or three!

@neilc  I'll take some measurements tomorrow.  I normally always do a basic design in Sketchup, but didn't this time. I figured that the welded tubular design wouldn't be precise enough  from saw to saw, so I just winged it.  I used a straightedge clamped to the table surface as a datum and referenced from that as I went.  I'll update after I can get some useful numbers

Offline neilc

  • Posts: 2834
Re: Quick Compact Outfeed Table for DeWalt Portable Saw
« Reply #4 on: July 26, 2018, 09:43 PM »

Offline Wooden Skye

  • Posts: 1171
  • My little girl was called home 12-28-15
Re: Quick Compact Outfeed Table for DeWalt Portable Saw
« Reply #5 on: July 26, 2018, 10:15 PM »
Nice work Dick!
Bryan

TS 55, (2) 1400 Guide Rails, 1900 Guide Rail, MFT/3, Domino ETS 150/3, RO 90, CT 26, OF1400, RO 150. RTS 400, LR 32 set, PS300 jigsaw, 3 abrasive systainers, (2) sys toolbox, (2) sys mini, clamps and other accesories

Offline DynaGlide

  • Posts: 761
Re: Quick Compact Outfeed Table for DeWalt Portable Saw
« Reply #6 on: December 03, 2019, 10:20 PM »
@Dick Mahany Are you still enjoying this setup? I just finished setting up the DW7440rs for my DW745 saw. Floor to top of saw is 880mm. I'm thinking about cutting a one inch plywood base to raise the saw to 905mm allowing me to use an MFT/3 as outfeed.
Instagram @matts.garage

Offline Dick Mahany

  • Posts: 551
Re: Quick Compact Outfeed Table for DeWalt Portable Saw
« Reply #7 on: December 04, 2019, 08:55 AM »
@Dick Mahany Are you still enjoying this setup? I just finished setting up the DW7440rs for my DW745 saw. Floor to top of saw is 880mm. I'm thinking about cutting a one inch plywood base to raise the saw to 905mm allowing me to use an MFT/3 as outfeed.

@DynaGlide I use the outfeed table regularly and it works great for my purposes.  I was concerned whether it would make the saw tippy however the splayed legs on the 7491RS are incredibly stable and the setup is solid.  I have not run full size sheets of 3/4" ply across it though which might be the ultimate test.  I use my track saw for breaking plywood sheets down. 

I'm guessing your DW7440RS is as stable as the DW7491RS and while the outfeed table would work well, I like the idea of the MFT3 table as an outfeed table.  It seems like my MFT3 is always occupied with something being clamped, assembled or cut so that wouldn't work in my typical setup. 

If interested, I documented the build process and annotated pics with dimensions in a PDF that I would freely share.

Offline DynaGlide

  • Posts: 761
Re: Quick Compact Outfeed Table for DeWalt Portable Saw
« Reply #8 on: December 04, 2019, 09:19 AM »
@Dick Mahany Are you still enjoying this setup? I just finished setting up the DW7440rs for my DW745 saw. Floor to top of saw is 880mm. I'm thinking about cutting a one inch plywood base to raise the saw to 905mm allowing me to use an MFT/3 as outfeed.

@DynaGlide I use the outfeed table regularly and it works great for my purposes.  I was concerned whether it would make the saw tippy however the splayed legs on the 7491RS are incredibly stable and the setup is solid.  I have not run full size sheets of 3/4" ply across it though which might be the ultimate test.  I use my track saw for breaking plywood sheets down. 

I'm guessing your DW7440RS is as stable as the DW7491RS and while the outfeed table would work well, I like the idea of the MFT3 table as an outfeed table.  It seems like my MFT3 is always occupied with something being clamped, assembled or cut so that wouldn't work in my typical setup. 

If interested, I documented the build process and annotated pics with dimensions in a PDF that I would freely share.

@Dick Mahany That would be great I'd like to see the PDF. You can grab my email via PM if you're willing to share, or if there's a way to link to it for others as well.

I have two MFT/3's dedicated to working and a third that's a floater for whatever I need that stays folded up. I know that sounds excessive but I bought them all second hand at about half off. If you were to get an MW1000 extension table you could do what I'm attempting without tying up your MFT/3.

When I built my Vac Sys cart I made the height of it slightly higher than an MFT and it comes in at about 905mm floor to top. It's on wheels and I could see moving it up to the saw when I need it for outfeed. Yes the stand I purchased is incredibly stable. The splayed leg design is impressive. I was keeping my saw on a shelf before and I don't have to tell you how inconvenient it was. I'm after a mobile setup that I can get going fast and put away just as quickly. I think between the improvements I made to the fence and this mobile outfeed I'm after I'll have one slick setup that can go outside with an MFT/3 if I want it to.

Matt
Instagram @matts.garage