View Full Version : Outfeed Table for DeWalt 7491RS Portable Saw Part 1

Dick Mahany
08-30-2018, 10:41 AM
At the suggestion of Lee Schierer from a post in a different forum, here is an outfeed table for the DWE 7491RS portable saw. The table cantilevers from the rear tubular frame of the saw and doesn't interfere with the rack and pinion rear drive guide for the rip fence. It assembles and lifts onto the saw in seconds and stores compactly for ease of transport or storage when not needed. I normally like to do a Sketchup design first, but didn't in this case, and just winged it ;).

The table measures 26.5" square

The parts store compactly and are easily transported.

Assembly is quick.

A straight edge makes a convenient reference for measuring and positioning for the support wings.

The wings provide the support for the table Additional legs are optional although I have not needed them.

A cross member provides for rigidity and locates the table to maintain repeatable clearance from the rip fence guides. A good fit between the notches in the wings and the cross member is important for stability and ease of assembly.

Since I have reached the picture limit, I'll continue the rest of the build in Part 2............

Dick Mahany
08-30-2018, 10:43 AM
Here are the remainder of the pictures from the previous Part 1 post.........

The side blocks control the angle of the wings to maintain the parallelism of the outfeed table to the saw table. I used a scrap off cut from the table material as a spacer between the straight edge and the top of the wings and simply used brads and glue to attach the sides blocks into position. I had thought about making them adjustable, but it turned out not to be needed and this was quick and secure.

Once the table is completed and installed the miter slots can be milled.

I don't have plans per se, however I have annotated pictures of the parts with measurements below.
Most of the dimensions are non critical and simply provide for clearance. The most critical dimension is the location of the arc that hangs the wing on the horizontal frame tube member and the distance to the top of the wing from that arc since it will determine the height of the outfeed table surface.

The portable table saw is often maligned for having a small table. It is just the nature of compromises that have to be made to keep these saws relatively compact for ease of portability. While an outfeed table won't help on the front side, it does make a substantial improvement to the saw's overall utility. If you are interested in more details, I have a PDF that outlines more. Simply PM me with an email address.

EDIT: Just for clarification, the wings don't have to extend down as low as mine do. I was originally thinking about making an adjustable tilt mechanism on the bottom of the wings that would bear against the rubber saw feet. I decided that wasn't necessary but never cut the bottom of the wings (where the corner notches are shown).

Lee Schierer
08-30-2018, 6:25 PM
Thanks Dick, nice write up for a very nice accessory.

Marlin Spencer
09-25-2018, 7:32 PM
Dick, this is awesome!! I really appreciate the images as well as the extra photos with measurements. I just got my 7960x and will definitely be making this.

Dick Mahany
09-25-2018, 8:51 PM
Dick, this is awesome!! I really appreciate the images as well as the extra photos with measurements. I just got my 7960x and will definitely be making this.

Welcome to the Creek and glad they helped.

Ken Fitzgerald
09-25-2018, 9:23 PM
Nicely done Dick!

Dick Mahany
11-28-2018, 12:18 PM
A question was asked if the outfeed table as built could remain on the saw in the vertical storage position. The answer is yes it can, although it is so easy to remove that is isn't apparent why that would be helpful.


Dick Mahany
12-30-2018, 9:09 PM
Just checking to see if anyone has built their own version of this outfeed table.......Would love to see pics if anyone has made improvements to it or if it was adapted to other makes/models. Comments/critiques are most welcome :)