An outfeed table catches material as it exits the table saw, preventing boards from tipping off the back and pulling the cut off-line. Without one, ripping a full sheet of plywood solo is dangerous and inaccurate. Building an outfeed table that also serves as an assembly surface makes the most of your shop space.

Build a Table Saw Outfeed Table

Critical Dimension: Height

The outfeed table surface must be exactly the same height as your table saw top, or up to 1/16 inch lower. If higher, material catches on the edge and disrupts the cut. Measure from the floor to the table saw surface and build to that dimension.

Simple Build

Frame

Build a rectangular frame from 2x4 lumber:

• Length: 36 to 48 inches (depth behind the saw)
• Width: 48 to 60 inches (matches or exceeds the table saw width)
• Height: Match the table saw top exactly

Use lap joints or pocket holes at the frame connections for a strong, flat structure. Add a lower shelf at 6 to 8 inches from the floor for storage and stability.

Top

Use a sheet of 3/4-inch MDF or melamine for an extremely flat, smooth surface. MDF is affordable, stays flat, and provides a slick surface that material slides across easily. Apply a coat of paste wax for even better slide.

Screw the top to the frame from below so the top surface remains smooth and uninterrupted.

Mobility

Mount locking casters on the legs. Roll the table behind the saw for rip cuts, then reposition it elsewhere as an assembly table for woodworking projects.

As an Assembly Table

When the outfeed table is not serving the table saw, it becomes the shop’s assembly surface:

• Flat reference surface: MDF provides a reliably flat surface for checking assemblies
• Clamping access: Add a row of 3/4-inch bench dog holes along the edges for holdfasts and bench dogs
• Sacrificial surface: If you damage the MDF top with glue, cuts, or stains, replace it in 15 minutes for $15

Torsion Box Option

For an absolutely flat surface that never warps, build a torsion box top:

1. Cut two sheets of 1/4-inch or 1/2-inch plywood to size
2. Build an internal grid of 2-inch wide plywood strips, spaced 6 inches apart
3. Glue and clamp the top and bottom skins to the grid

A torsion box is lightweight, extremely stiff, and stays flat for decades. It is the premium option for an assembly/outfeed table.

Sizing

If your shop layout allows, build the outfeed table large enough to support a full 4x8 sheet of plywood as it exits the saw. This means the table should be at least 48 inches wide and 36 inches deep (behind the saw blade).

If space is limited, even a 24x48 inch table makes a significant difference in safety and cut quality.

Bottom Line

An outfeed table is a safety essential for any table saw setup and a multipurpose work surface the rest of the time. Build one from a 2x4 frame, an MDF top, and locking casters for under $50. It is one of the most-used fixtures in any workshop.