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No cutting of fixed table board was required. I welded them up and re-painted the bottom of the foot and all is well. Only complaint was that one of the spot-welded threaded leveler feet tabs snapped right off. I easily installed the outfeed table on my newer Delta Unisaw w/ 52" Biesemeyer fence (36-816). Holes were already present for mounting. Packing and shipping was fine -- no shipping damage. Works great, stores out of the way, very solid.
I got this when I ordered my Delta saw several years ago. The unit seems to have developed a slight bow with time. After using it, I've decided to build my own.
The simplest solution was to just put a wood block under the vertical brace made of glued 2x4 pieces. After making this cut (allowing for about an 1/8th inch fence clearance), I assembled the stationary top in place, aligned it and checked for flatness and tightened the bolts. I then marked the 4 holes to be drilled and where I would need to add a horizontal brace along the lower part of the table saw stand. I have posted pictures of how I set mine up. Problem solved.This is a really great table extension and I'm very happy with it. You also don't need 2 people, because one end can rest on the floor while you insert the screws.
The pieces have a lot of adjustment built in by using slotted holes, so as long as you get the 4 holes drilled in the right place on the table saw, you can get it aligned. Precise alignment (as suggested in the original instructions) was not needed. The extension also doesn't get in the way of using my Bench Dog router extension. This project took 3 hours, with 1 hour spent on thinking about assembly and test fitting the pieces with 2 hours spent on actual assembly. It converts my TS300 into a professional level saw. I bought this knowing it was not designed for my Delta TS300, but I also knew that it was modifiable. This brace I made out of a 2x4.I then disassembled the parts and started assembling it directly to the table.
You do have to be careful though to align at least one slot for your miter/cross-cut slide. I basically threw away the instructions after reading through it once to get the basic idea of how the parts fit together. My TS300 is on a wheeled stand, so the vertical brace is not long enough. I then assembled the stationary subassembly part of the table and test fitted it to my saw. I don't need both channels, but if I did I could cut out a section of the stationary table top with my router.Once I got the metal pieces bolted in place, I again test-fitted the stationary table top piece to make the final mark for cutting off the edge so that I had clearance for the fence slide. I took my time and didn't rush, and measured twice before drilling or cutting anything. Adding the big folding table to the hinge was then trivial and required no adjustments or cutting.
This outfeed table fit right up to the saw perfectly. Plus, it folds down. not much to say about this product other than it was packaged just fine for my delivery. The stationary portion of the table actually is pretty useful as well, allowing medium sized stock to safely exit the cut. If you do get a good package, then you'll be very happy with what is in the box. It was worth my time and effort to make this a bargain purchase. If you can build one yourself, you'll save some money, but not much with the cost of the legs and bracketry.
Unfortunately, it may not hold true for others I guess. It adds a great deal of safety to the cutting of longer stock, and I highly recommend it as a purchase. I would recommend using a router and straight edge to extend the miter slots into the folding portion of the table as well, allowing the use of a cross cut sled or extended miter gauge setup. This is an easy assembly, as well.
I'm not sure way so many have received them with broken pieces. Just know it can be done if you use the Delta instructions and a little ingenuity.I ripped about an 1 1/2" off the 12" short stationary piece to fit in between the tablesaw top and end of the Delta supports. Then chamfered the lead edge of that short stationary piece. The small stationary support has rabbets to clear the miter slide and because its always in place its very handy for pieces less than 48". I also widen the rabbet on the short stationary piece to line up with the Sawstop miter slots which differ slightly from the Delta's. Well currently the only ready made flip up/down outfeed for the Sawstop is a pivoting roller rack, which is almost identical to the one I put on my old PM66. Now I know that if the guard is in place this isn't a problem, but I use a lot of jigs that don't work with a guard. That's way I bought a Sawstop which has at a riving knife in place most of the time and a blade brake all the time.The modifications are relatively simple.
Maybe Delta improved the packing.You might ask why I would go through the trouble of modifying the Delta outfeed. You may need to do a partial assembly to estimate the location before drilling the holes. Thanks to that reviewer for the heads-up. I took some work but its well worth it.
By placing the holes for the left supports an inch or two off the left edge, all the slotted brackets line up pretty good. This outfeed is an excellent buy for a small shop when you consider just the cost of the hardware. I modified this Delta outfeed table to fit my Sawstop tablesaw. Mine was packed well and received in perfect condition. Its was a very sturdy unit but I didn't like the roller rack because it let small work pieces fall through or wedge between the rollers, and I had to constantly lower it to clear the miter slides on jigs/guides. I did that before installation because that was mentioned in a previous review.
I am not going into detail on the dimensions because you'd need a drawing to give you every detail. The flip up/down extension is great for safely and accurately ripping long boards and sheet goods. If you forget to raise it back up, boards can and do slide back towards the blade. I eventually replaced the stock piece with a custom plywood and laminate piece 7/8" thick with narrower rabbets in the exact location. Viewing the saw from the outfeed looking towards the saw's back, there is a space between the 4" dust connection and the conduit box where you can install the right vertical support.
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