Multi-Use Outfeed and Assembly Table

Multi-Use Outfeed and Assembly Table

 

I needed a simple but versatile table for my shop to use for assembling projects.  At the same time, I was contemplating how to create an outfeed table for my saw that would be out of the way when not in use.  The answer, a multi-use outfeed and assembly table.  If I can use the assembly table as an outfeed table, I don’t need two tables.

The table is 48" square and cut from 3/4" plywood.  The legs are simple 2" x 4" pine construction.  I made a square frame of 1" x 3" Oak, joined together by pocket holes, 40-1/2" inside diameter and the 1" edge oriented up. The frame is smaller than the 48" square so that the edges of the table will be exposed around the perimeter to allow an edge to be used for clamping.  Also the inset clears the motor on my contractor saw when the table is used for an outfeed table behind my saw.

The table legs were cut so the table exactly matches the height of my table saw at 35-1/2". 

 

A second frame was made matching the first. The frames had the legs attached inside each corner with 2-1/2" screws. The top frame was held even with the top of each leg. The second frame was mounted 16" below the top to create a shelf under the top. The shelf was made from the second half of the 3/4" plywood sheet and cut down to 42" so it did not extend beyond the legs. Notches were cut in each corner to clear the upright legs. The shelf was put in place before permanently fastening the lower frame. The top and shelf were attached using pocket holes in the frames and screws from underneath so the screws do not extend above the table or shelf surface.

 

The shelf at 16" below the top allows a copy paper box to fit nicely on the shelf with a bit of clearance.  As well as an outfeed and assembly table, with the addition of the shelf, storage for light items in copy paper boxes is possible.  As an example, I keep safety items such as glasses, knee pads, dust masks, etc., in one of the boxes. I also store the rip fence to my table saw and a couple of framing squares on the shelf. 

I rounded over the table edges with a router and 3/8" round-over bit so the edges are not sharp.  The overhang comes in handy when I need to use clamps in assembly.

 

Normally, the table sits directly behind my saw with a foot or so of clearance.  When I use it as an outfeed table, I simply slide it up against the back of the table saw top.  If I am cutting longer pieces, the table can stay in place and not have to be moved from the position where it is used for assembly.

 

I have used strips of wood screwed directly into the surface of the table when I need to create a jig to hold something in place.  For example, when making cutting boards, I screwed 1" material at a 90° angle.  I put down packing tape and had an easy glue proof assembly corner for the cutting boards.

 

The wooden top of the table is easy to maintain.  I sprayed it with a light coat of polyurethane.  If it becomes dirty or stained, I light sand with an orbital sander and 100-grit sandpaper to bring it back to clean and reapply the poly.

 

I find I use the table more than my workbench, since the table has lots of room to work and is centrally located in my shop.