Table Saw Outfeed Roller

This is my first instructable so be gentle please. I am constanly working with larger sheets of material. I have a small table saw and it is always a pain to work on such a small area with such a large piece. I always save bits and parts from previous projects and while looking at what I had I figured I could come up with something to make life easier.

You will need:
1X3 ½ board. Length depends on your saw horse
1 ¼ “ X 5 SCH 40 PVC. Length depends on your saw horse
2 bolts at least 2 inches long with 2 washers and 4 nuts (I used 1/4 inch)

Tools:
Hole saw 1 1/2"
chop saw or hand saw

Step 1: Uprights

Start by using a hole saw to make two plugs. I used a 1 ½” saw which made plugs that fit nicely inside my 1 ¼ “ X 5 SCH 40 PVC. Make two of them.

Step 2: Uprights

Cut a piece 6 inches long. Find the center line and measure down 5/16” and drill a hole there using the same size bit as your hole saw.  Cut a 45 degree piece off each corner near the hole you just drilled.The final piece should look like this. You will need to make two of these.

Step 3: Uprights

Assemble the up supports by first installing a bolt from the outside like this

Then add one of the wooden plugs

Next add a washer

Finish by adding two nuts. Put the first one on and leave about a 1/16 space between it and the washer. Put the second one on and tighten it against the first one. This will allow the plug to spin without binding up. Repeat for the other side.

Step 4: Cross Piece

Cut a piece of the 1X3 ½ long enough to fit between the down supports of your saw horse. Make sure you leave at least a inch of space on each side. This will be the cross piece.

Step 5: Add the Roller

Attach both uprights to to the cross piece as shown in the picture
.
Once assembled measure the distance between the up rights and subtract about a 1/8 of a inch.

Cut a piece of the pvc pipe to that length.



If you want, now is the time to paint all the parts, minus the pvc. I just used some black spray paint I had left over from a previous project.

Step 6: Final Assembly

Now it is time for final assembly. If you took the uprights apart to paint, assemble them as before, this time leaving one of the uprights off of the cross piece.

Slip the pvc over the wooden plug on the attached upright.

Attach the second upright while at the same time inserting the pvc onto the second wooden plug.

Note: I used wood glue on my joints just out of habit.

Step 7: Put Into Use

The roller is complete. Now you just need to attach it to the saw horse. I use a squeeze clamp just to hold it in position and then add a twist clamp to both sides to really lock it in place.


Hope you find it useful