I have a project coming up that will require a long resaw cut on my band saw. Resawing is where you sit a board up on its skinny side and cut down the length. I love my bandsaw, but when it comes to doing long work the small table has left me in the lurch. The bandsaw is a tall tool so that most roller type outfeed supports don’t come close to high enough. I am going to add a removable outfeed table to the back end to help with these kinds of scenarios.
I have some phonelic resin covered plywood that makes good slick surfaces for things like this. The resin surface can chip off if hit on the edges though. I made a frame to hold the plywood, protect the edges, and give me a place to bolt too. This could have been done in pine, but I am trying to increase the quality of my infrastructure work, so I went with maple instead. I routed a groove on the router table and used my roundover templates to make the corners match on the plywood insert.
After gluing and pinning it through the side I did a careful trim with a block plane to get the outside frame and inside surface to be perfectly flush. This made fun little corkscrew shaped shavings. Now anything sliding across wouldn’t get caught on a lip or edge, and the sides of the plywood will remain protected. This is another place where hand tools make the job a lot safer and less likely to induce disasters than something with a motor would do.
With the table top complete I needed a support leg to help keep the back end from sagging. Making it screw together let me turn two short pieces of plywood into a longer one, and helped with fine tuning the outfeed level.
A hinge attaches the support leg to the under side of the table top. There was a good place for the bottom of the foot where the bandsaw base meets the cabinet it sits on. This will let the table support a decent amount of weight without sagging.
The bandsaw’s table top has two bolt holes in the back that accept M6 screws. I got some socket head cap screws and bolted the front of the outfeed into the back of the cast iron top. The back support leg keeps the rest of the table top up under load. I finished everything with boiled lineseed oil and wax.
The table is almost exactly the same width as the iron top, but doubles the total length. Now I can resaw a 3ft board without worry about it dropping off the back end. As a bonus, the outfeed table doesn’t interfere with anything behind it when pushed into its resting place. Nor does it interfere with the fence. Basically I will probably never take this off.