If you have a smaller hobby table saw, and you have to cut long workpieces.
Soon you will notice that the small surface of your table saw is not that handy.

If the longer pieces are too far beyond the worktop, they will tend to tip over. 

Absolutely not safe!!!

To avoid this, Your workpiece must be supported.
However, not every workshop is that large that you can easily place an outfeed table behind your table saw.

Therefore, this is the solution for smaller workshops: an adjustable outfeed stand.

Thanks to the 3 rollers, this outfeed stand provides stable support for your larger workpieces.

Download the free plans, and build this DIY outfeed stand as a project for your workshop.

Watch the outfeed stand video here

Building the DIY outfeed stand step by step​

Now that we have gone through the list of what we all need for this project, I will explain step by step how to make this adjustable outfeed stand.

Let’s go!

Step 1 | Preparation

Note:

Later in this project, I will use a square bar for the inner part of the outfeed stand. 
I used 2 leftovers from a board that I had in my scrapwood cart for this.

If you have a bar with the dimensions indicated on the plan, you can use this.

If you have to glue boards for this, just like me, you should do this at the beginning of this project. 
That way the wood glue is dry when you need this part.

To start this project, you can use the free plans that you can download in this blog.

With the dimensions on the free plans, you can prepare all pieces for this stand.

I used my table saw and crosscut sled for this.

Step 2 | Making the base​

Preparing the boards​

The base of the rollers for this outfeed stand consists of 2 boards with ball bearings in.

The ball bearings I used have a diameter of 22 mm. 
First I made a hole 7 mm deep with a 22 mm drill.
The ball bearing fits in this hole perfectly.

In the center of that hole, I drilled through the board with an 8 mm drill through which the threaded rod fits.

After drilling the holes I carefully placed the ball bearing in the holes.
Do not use a metal hammer for this, otherwise, you will damage the ball bearings!

Making the rolls​

The rollers for this outfeed stand consist of a PVC tube with a diameter of 50 mm.
The openings of the tube were filled with a wooden disc that I made with a hole saw.

To fix the wooden discs in the tube I used CA glue.

Once the discs were in the correct position, the adhesive was activated with the accelerator.

In the middle of the wooden discs, there is an 8 mm hole.
Through this hole, the threaded rod can be slid to mount the rollers on the outfeed stand.

Over the threaded rod, I placed a washer on both sides.

Make sure that the washer is not larger than the inner ring of the ball bearing.
If not, you clamp the ball bearing, and it will not work smoothly.

Assembling the rollers​

To keep the 2 boards with the ball bearings at the correct distance from each other, these are connected to each other by 2 small boards.

These boards must be lower than the top of the rollers.
If they are higher, they will slow down the workpiece that must slide over the rollers.

First I attached the boards to one side of the outfeed stand.

Then I placed the rollers in the ball bearings and placed the second board on top, so that the rollers were fixed.

The boards were fastened together by screws.

Step 3 | Bracket​

You can make the parts of the bracket as indicated on the plans.

Earlier I had drilled a hole in the base for the rollers.
That is where I could fix the bracket with a bolt and homemade buttons.

The parts of the bracket were fastened together with wood glue and screws.

Always pre-drill with a drill bit that is slightly smaller than the diameter of your screw.
This to avoid splitting the wood.

Step 4 | Making the knobs​

To fix the bracket, and later also the height-adjustable position, I use homemade wooden star knobs.

In these knobs, I press a T-nut.
That way, I can easily use these knobs on a bolt to tighten some parts together.

Step 5 | The adjustable stand​

The stand consists of two parts: a fixed outside and an extendable inside. This makes it possible to use this outfeed stand in different heights.

In order to be able to fix the two parts together, a slot is made in the fixed outside.

A nut is mounted in the movable part in the inside of the outfeed stand.

By turning a homemade knob with an integrated bolt through the slot into the nut, you can clamp the two parts together.
That is how you can determine the height of the outfeed stand position.

I made this slot with a very simple jig I made for my router.
You can see how I made that jig in my video: Simple router jig.

The parts for the outside of the stand were fastened together with wood glue and bradnails.

If you do not have a nail gun, you can also use nails or screws.

A movable foot will be placed at the bottom of the outfeed stand.

By hinging this foot, it will always remain in full contact with the ground, no matter how wide you put the leg of the stand.

The parts of the foot are attached to each other with wood glue and screws.
To place the foot on the stand I used wood bolts.

To support the stand and in this way also ensure the strength of this outfeed stand, 2 legs are mounted on spacer blocks.

In this way they do not come into contact with the bolts of the foot, and the legs can be made as long as possible.

To keep the legs equally spaced and also to make them more sturdy, they are connected with a piece of wood.

To prevent the legs from slipping, they are held in place with a ribbon.

In this ribbon, I made several holes so that the distance at which the legs can be placed is adjustable.

The holes in the ribbon were made with hole pliers.
If you don’t have this, you can always try to make a small cut in the ribbon.

Step 6 | Assembling the outfeed stand​

Now that all parts were made I could assemble.

First, the bracket was mounted on the stand.
For this, I used wood glue and screws.
To keep the parts in place while screwing I used brad nails.

I only had to assemble the outfeed rollers and I could use my outfeed stand.