ROCKLER 65575 Table Saw Outfeed Kit Instructions

ROCKLER 65575 Table Saw Outfeed Kit

GENERAL SAFETY WARNINGS

This product is designed only for specific applications as defined in the instructions and should not be modified or used for any manner not described in these instructions. Use only recommended accessories. Before using the Table Saw Outfeed Kit: READ, UNDERSTAND and FOLLOW ALL INSTRUCTIONS AND SAFETY WARNINGS. KEEP THESE INSTRUCTIONS READILY AVAILABLE FOR FUTURE REFERENCE.

Always confirm that you are using the most recent version of the Instructions and safety warnings for your product (see the Instructions link on the product page at Rockler.com).

Before using another tool with this product, always read, understand and follow the instructions and safety warnings in the owner’s manual for that tool. If you do not have the owner’s manual, obtain one from the tool’s manufacturer before using it with this product.
Before using any chemical with this product, always read, understand and follow all safety warnings and guidelines in the manufacturer’s Safety Data Sheet (SDS; formerly called “MSDS”), especially regarding:

• How to safely use the chemical, including potential hazards and recommended first aid measures;

• Personal safety equipment required to safely use the chemical (e.g. gloves, eye protection, mask/respirator, etc.);

• Proper and safe handling, storage and disposal of the chemical.

  Before using this product, review and verify that all tools to be used with it have safety equipment installed and are in proper working order as defined by the tool’s owner’s manual.
  Do not use this product until you have read and are confident you understand:

• Product Specific Safety Warnings (p. 3); · Assemble the Bottom Section of the Cabinet (pp. 3 – 7); · Assemble the Dust Bucket (pp. 8 – 10);

• Mount the Dust Bucket (pp. 10 – 11);

• Installing Safety Power Tool Switch Bracket (pp. 11 – 13);

• Attaching the Cabinet Top and Doors (pp. 13 – 14);

• Attaching a Router Tabletop (pp 14 – 15).

  The user assumes all risk and responsibility for the proper and safe use of this product and for ensuring product suitability for the intended application.
  It is the sole responsibility of the purchaser of this product to ensure that anyone you allow to use this product reads and complies with all instructions and safety precautions outlined in this manual prior to use.
  Follow all standard shop safety practices, including:

• Keep children and bystanders away from the tool operating area; · Do NOT use power tools in explosive environments, or in the presence of flammable liquids, fumes or dust; · TURN OFF AND UNPLUG all power tools BEFORE making any adjustments or changing accessories;

• Remain alert and use good judgment. Do not use this product if you are in any way impaired by medications, alcohol, drugs or fatigue;

• Keep your work area well lit and clean;

• Dress appropriately. Secure loose clothing, remove all jewelry and tie up long hair before using this product;

• ALWAYS wear safety glasses, hearing protection and respiratory protection that complies with NIOSH/OSHA/ANSI safety standards;

• Use dust collection tools and dust face masks to reduce exposure to dust;

• Use safety equipment such as featherboards, push sticks and push blocks, etc., when appropriate;

• Maintain proper footing at all times and do not overreach;

• Do NOT force woodworking tools.

  These warnings and instructions do NOT represent the total of all information available regarding tool safety, use and technique. Always seek out opportunities to learn more and improve your skills and knowledge.

Drilling, sawing, sanding or machining wood products can expose you to wood dust, a substance known to the State of California to cause cancer. Avoid inhaling wood dust or use a dust mask or other safeguards for personal protection. For more information go t www.P65Warnings.ca.gov/wood.

Danger indicates a hazardous situation that, if not avoided, will result in death or serious injury.
Warning indicates a hazardous situation that, if not avoided, could result in death or serious injury.
Caution indicates a hazardous situation that, if not avoided, may result in minor or moderate injury or property damage.

Notice indicates important or helpful information and/or user tips.

PRODUCT SPECIFIC SAFETY WARNINGS

Any table created with the Table Saw Outfeed Kit is NOT intended to serve as a workbench ­ only as a table to support material being cut on the table saw.

The maximum weight capacity per pair of brackets and legs depends on the material used for your tabletop. Under no circumstances should the load on the table exceed 150 lbs., including the weight of the tabletop.
To avoid pinching or crushing your fingers, always keep your hands clear of the leg folding mechanism.
Before using tabletop, both Adjustable Leg Assemblies (15) must be deployed and locked, and BOTH Tabletop Brackets (10) MUST be secured to the Height- Adjustment Brackets (6) with the Safety Locking Pins (11).
Do NOT sit or stand on tabletop or allow children to climb or play on or under the tabletop; keep pets away.
Ensure table feet are positioned flat; do not use on sloped or uneven ground.
To avoid tipping, do not overload table; make sure load is centered on table surface.
The maximum weight capacity per pair of brackets and legs depends on the material used for your tabletop. Under no circumstances should the load on the table exceed 150 lbs., including the weight of the tabletop.
Minimum tabletop thickness: 3/4″
Maximum tabletop thickness: 1½”, depending on your saw
The tabletop must have a surface that allows workpieces to slide smoothly across it. Any irregularities on the surface of the tabletop that could catch a workpiece could cause dangerous kickback.
Always make sure that the outfeed table height is precisely at or slightly below the level of your saw’s table and that the tabletop is parallel to your saw’s table.

Make sure to fully tighten all fasteners.
Do NOT attempt to lift more than you are physically able. Get help if necessary. Use proper lifting techniques.

PARTS LIST

1. Saw Bracket 2
2. 3/8″ Hole Insert 2
3. 1/4″ Hole Insert 2
4. 5/16″-8mm Hole Insert 2
5. 9mm Hole Insert 2
6. Height-Adjustment Bracket 2
7. M6 x 20mm Carriage Bolt 4
8. Flat Washer 12
9. M6 Nylon Insert Locknut 12
10. Tabletop Bracket 2
11. Safety Locking Pin (with Lanyard) 2
12. #10-24 x 3/8″ Panhead Machine Screw 2
13. #10-24 Nylon Insert Locknut 2
14. #10 x 1″ Panhead Wood Screws 8
15. Adjustable Leg Assembly 2
16. M6 x 50mm Flathead Bolt 8

The Table Saw Outfeed Kit is NOT compatible with jobsite table saws or with contractor table saws that have a rip fence that secures on both the front and rear rails. It is compatible ONLY with table saws that have a Biesemeyer-style rip fence that secures only at the front of the saw.

Attach Brackets to Table Saw

The rail at the back of your table saw is secured to the main body of the saw and the table extensions with bolts and nuts. You will need to remove two of these bolts and nuts to attach the Saw Brackets (1).

1. Locate the two bolts that will be outermost on the saw, but still within the width of your outfeed tabletop.
2. Remove one of the two bolts, taking care that the table extension on that side doesn’t shift.
3. Find the correct Hole Insert (2, 3, 4 or 5) for the mounting bolts on your table saw; choose the insert whose hole is closest in diameter to the bolts. Note that the holes in two pairs of Hole Inserts (3 and 4) are off-center; this is to allow you to place the holes at the top or bottom, depending on the orientation of the rear rail on your saw and the needed clearance for the head of the mounting bolt.
4. Hold the Saw Bracket (1) up to the saw’s rear rail, aligning the holes. Insert the correct Hole Insert (2, 3, 4 or 5) in the Saw Bracket, and then feed the mounting bolt from your saw through the hole. Thread on the nut and make sure the bracket is square to the top; then fully tighten the bolt. Fig. 1
5. Repeat Steps 2-4 to attach the other Saw Bracket (1) to your saw at the other mounting bolt location.
6. Attach the Height-Adjustment Brackets (6) to the Saw Brackets (1). Orient each Height-Adjustment Bracket so the hooked end is at the top and the hook opens away from the saw. Insert two M6 x 20mm Carriage Bolts (7) in the square holes in the back face of the Saw Brackets and through the slots in the Height-Adjustment Bracket. Attach loosely with a Flat Washer (8) and M6 Nylon Insert Locknut (9) on each Carriage Bolt. Fig. 1.
7. Raise each Height-Adjustment Bracket (6) as high as it will go and snug the M6 Nylon Insert Locknuts (9). You will fine-tune the position of the Height-Adjustment Brackets later.

About the Tabletop

You will need to build a top to serve as your outfeed table. The length and width depend on the size of your saw and the available space in your work area. Important: The maximum thickness of the top depends on your saw. The minimum thickness is 3/4″. To determine the maximum thickness for your saw, first measure the distance from the surface of your saw’s table to the top flat surface of the Saw Brackets (1) you attached to your saw in the previous section. Then subtract 1/2″ from that figure. The resulting measurement is the maximum thickness of your top. For example: If the vertical distance from your saw’s table to the bracket is 1¾”, subtract 1/2″ from 1¾” to arrive at 1¼” as the maximum thickness for your table. If you make the table thicker than 1¼”, its surface will end up higher than the surface of your saw’s table, rendering the outfeed table useless. The surface of the outfeed table must always be flush with or slightly below the surface of the saw’s table. Having an outfeed table that is higher than your saw’s table is dangerous and could result in kickback and serious injury. Here are some additional things to keep in mind as you design your tabletop:

• One dimension of the tabletop must be at least 26″ to allow the Adjustable Leg Assemblies (15) to retract and fold up within the area of the top.

• The Table Saw Outfeed Kit is designed so the table can be removed from the saw and stored with the legs folded up. To minimize the chance of injury, the tabletop needs to be of a size and weight that you can maneuver without difficulty.

• Choose a surface for the top of your tabletop that will allow workpieces to slide smoothly across it.

• If you plan to machine grooves into your tabletop to extend the miter slots from your saw, make sure the tabletop is of sufficient thickness so that the grooves don’t compromise its integrity.

• Rout a chamfer or round-over on the leading edge of the outfeed tabletop (the edge closest to the saw) to help reduce the chance of workpiece catches.

Attach Legs to Tabletop

1. Place your tabletop topside down on a smooth work surface.
2. Determine how you need to orient the legs so that they will fit within the area of the tabletop when retracted and folded up for storage. Note that if they will fold toward each other, their mounting positions must be offset so that they both can fold flat. Again, one dimension of the tabletop must be at least 26″ to allow the Adjustable Leg Assemblies (15) to retract and fold up within the area of the top.
3. Use the Leg Mounting Hole Template in the Shop Drawings (p. 9) to mark the locations of holes you need to drill to attach the Adjustable Leg Assemblies (15) to the tabletop. Note that the template includes guides for creating a 1″ setback from the tabletop edges. Keep in mind that if the Adjustable Leg Assemblies (15) will fold toward each other, their mounting positions must be offset.
4. With the top still topside down, drill 9/32″ diameter holes all the way through the top at the marked locations. Place a sacrificial backer piece under the drilling locations to minimize blowout and take care to drill the holes as straight as possible. If necessary, use a drill press or drill guide, such as the Portable Drill Guide (52885, sold separately).
5. Flip the tabletop right side up. Chuck a countersink in your drill to ease the edges of the holes you just made so that the heads of the M6 x 50mm Flathead Bolts (16) used to mount the Adjustable Leg Assemblies (15) to the tabletop will sit flush to the surface.
6. Double-check that you’ve oriented the Adjustable Leg Assemblies (15) correctly; then attach each Leg Assembly to the tabletop with four M6 x 50mm Flathead Bolts (16), four Flat Washers (8) and four M6 Nylon Insert Locknuts (9).

Mount the Tabletop Brackets and Connect the Outfeed Table to the Saw

1. Measure the distance from the surface of your saw’s table to the floor. Then subtract the thickness of your tabletop from that number.

2. Unfold the Adjustable Leg Assemblies (15) until they lock in the open position. On each Leg Assembly, press the blue paddle nearest the bottom and pull on the leveler foot to extend the leg. (The slots allow you to extend the leg in 1″ increments.) Measure the distance from the bottom of the leveler foot to the underside of the tabletop, and keep adjusting the Adjustable Leg until the length is approximately equal to the final number from
   Step 1. Do this for both Leg Assemblies. (You might want to mark the slot setting for future reference.) Fig. 2 – 4.
   
   
   

3. Attach a Safety Locking Pin (11) and lanyard to each Tabletop Bracket (10) with one #10-24 x 3/8″ Panhead Machine Screw (12) and one #10-24 Nylon Insert Locknut (13).

4. At the table saw, fit a Tabletop Bracket (10) onto each Height-Adjustment Bracket (6) and secure it in place with the Safety Locking Pin (11). Fig. 5.

5. Carefully lift your outfeed tabletop, with Adjustable Leg Assemblies (15) deployed, and position it as desired at the back of the saw, resting the end opposite the legs on the Tabletop Brackets (10). The outfeed table probably won’t be level with your saw’s table at this point. Fig. 5

6. Loosen ­ but don’t remove ­ the M6 Nylon Insert Locknuts (9) on the M6 x 20mm Carriage Bolts (7) that secure the Height-Adjustment Brackets (6) to the Saw Brackets (1). Fig. 6 and 7.

7. Place a long carpenter’s level across your saw’s table and the outfeed table. Move the Height-Adjustment Brackets (6) up or down until the outfeed tabletop is aligned with (or slightly below) your saw’s table where the two meet. Snug the M6 Nylon Insert Locknuts (9). Fig. 6 and 7.

8. Make sure the outfeed table is in the final desired position. Working from under the tabletop ­ and being careful not to shift the table, the Adjustable Leg Assemblies (15) or the saw ­ carefully mark the eight screw hole locations for mounting the Tabletop Brackets (10).

9. Carefully lift the outfeed table off the saw and set it upside down. Drill 3/16″ diameter pilot holes at the marked locations on the underside of the tabletop, taking care not to drill all the way through.

10. Carefully lift the outfeed tabletop back to the saw and secure the Tabletop Brackets (10) to the underside of the outfeed tabletop with eight #10 x 1″ Panhead Wood Screws (14).

11. Use the carpenter’s level to check the outfeed tabletop and saw table front to back and left to right. Make any necessary adjustments to the Height-Adjustment Brackets (6) and/or the leveler feet on the ends of the Adjustable Leg Assemblies (15) to fine-tune the outfeed table alignment. Once the outfeed table is level and flush to the saw table, make sure to fully tighten the M6 Nylon Insert Locknuts (9) and the nuts on the leveler feet.

Removing Outfeed Table for Storage

1. Pull both Safety Locking Pins (11) to release the Tabletop Brackets (10).

2. Carefully lift the tabletop away from the saw and set it upside down on the ground.

3. On each Adjustable Leg Assembly (15), press the blue paddle nearest the leveler foot and carefully allow the leg to fully retract until it locks.
   

4. On each Adjustable Leg Assembly (15), press the blue paddle nearest the top bracket to release the mechanism and swing each leg to the closed position. Make sure the leg locks in the closed position.

5. Carefully move the table to the desired storage location.

Reinstalling the Outfeed Table

1. While balancing the table on its edge, unfold the Adjustable Leg Assemblies (15) until they lock in the open position. On each Leg Assembly, press the blue paddle nearest the bottom and pull on the leveler foot to extend the leg to the proper length (as determined during setup).
2. Carefully lift your outfeed tabletop, with Adjustable Leg Assemblies (15) deployed, and position it at the back of the saw so that the Tabletop Brackets (10) fit onto the Height-Adjustment Brackets (6). Secure them in place with the Safety Locking Pins (11).
3. Use a carpenter’s level to verify that the outfeed table and saw table are flush and level ­ especially if your saw is on a mobile base and the location of the saw has changed.
   Check Rockler.com for updates. If you have further questions, please contact our Technical Support Department at 1-800-260-9663 or support@rockler.com Fig. 7
   

Shop Drawings

Leg Mounting Hole Template

References

• Woodworking Tools, Hardware, DIY Project Supplies & Plans - Rockler
• P65Warnings.ca.gov/wood
• Woodworking Tools, Hardware, DIY Project Supplies & Plans - Rockler

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