So I have been wanting to build an outfeed extension wing for my upcut saw that includes a fence and stop. I want to build it out of steel or aluminum and I want it as flat, square and accurate as possible. It would need to have 8ft or 10ft length and be roughly 10” to 12” deep with legs on the far end and the other end or left end (it’s a right cut saw) will connect to a piece of angle iron mounted to the side of the saw. have a buddy that is a machinist and I plan to have him build it. I just need to come up with a design. That is where you guys come in. I need some ideas and opinions on how to do it.
One idea I had was to use 2” x 3” steel box tubing for rails that run the full length with a rail running perpendicular every 2 ft in the center connecting the two box tubing rails.then using a piece of steel plate for the top. The problem is that I don’t know if it would be absolutely dead flat. I paid a guy recently to build me one like this and he did a bad job as the top had a few significant dips and was overall not acceptable.
Another idea was to possible use some sheet metal formed in a brake wrapped over two 2” x 3” box tube rails in a similar fashion to above.
Do you guys have any better ideas or ways to improve on this? Accuracy and flatness are my biggest priorities.