Building an extension table.

I picked up a deal on a older delta table saw a week ago without a fence. I bought a mule accusquare for it.
Looking at setting it up and I am trying to figure out what to do about the extension table. The question now is do I build my own or do I buy one. Mule has one that will support a router for $129 including a router plate. since I have really a small shop I plan to have this table do double duty.
My original plan was to build my own out of a sheet of mdf. But I have some concerns.
My concerns were do I need additional bracing and how do I attach the mdf to the table and does it make sense just to buy a table?
For attaching the mdf to the table... current there are two stamped metal extensions bolted to the case iron table. This is easy to attach because the extensions are hollow underneath. If I used mdf how would I attach the mdf to the cast iron table and allow there to be some play to allow it to be leveled? Do I need to fram it out with some kind of u shaped steel that would allow me to screw the mdf to the steel and then to the table and allow me to adjust it? If so where could I get something like this? This is my biggest concern. I assume bolting the mdf to the fence only is not suffecient and it should be attached to the cast iron?
Also is the regular laminate that they sell in sheets at HD ok to put on the top to give it a smooth surface?
For the bracing.... I bougt a fence that is 10 inches to left of blade and 40 to the right. The delta table itself is real small, it came with two extensions but they are not cast iron and looked kinda beat up. If I can I would like to not even use them, I would rather just make the whole right of blade section of of mdf. I guess it is about 30 inches. I would rather not use extension legs at I have to roll the saw up a little hill in my basement to put it where I will store it. Does a fence of this size need support?
Ths moble base cant not be easily converted to support extension table legs plus even if it did I think this would be a problem with the un level floor in my shop. IF I need bracing I was planing on going up from the side of the mobile base to the edge of the extention table on a 45 degree angle with some tube steel. I think this will be fine with the exception that it only supports the table it does not keep the whole saw from tipping. To cover that I would probable add some legs that fold up that I could put down just when I was working to keep it from tipping. Is this a bad idea?
For the price.... does anyone have a extension table cheaper then $90 or one with a router plate for less then $129? Rich
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Rich wrote:

$129 isn't a bad price for what you're getting, and consider that the company that made your new fence is also the maker of the table..gotta fit I would think. Sounds like you have the stamped steel wings on the saw now, you can possibly switch those out for cast iron wings. I don't own the Delta but if you'll post the model# some of the others in the group might be of more help.
Scott
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You can make your own if you have the time. You'll save a little money. I plan to create a much larger cabinet with drawers and an integrated router and dust collection system, fold out extension tables in the front and back, all on casters. That should allow me to get away from the metal legs on the CS.

The table that came with my delta CS was particle board with a formica like veneer on both sides. not the greatest quality and certainly something you could make. The main thing is that you don't want the table to flex. it should remain flat. Some designes i've seen laminate the table with multiple 3/4" sheets. You could just brace it with something though. <snip about how to attach the table>
You could drill the cast iron. For my TS project, the router top will be part of a larger cabinet so I'm likely to have a leveling mechanism for the table saw and not connect them. The rails for your fence may have holes in them for the table. For mine, I think there's a back rail so that the table is attached front to back, not left to right.

That works but laminate both sides. I've never done it, but i hear that it will warp if you only do one side. I'm using melamine.

Think about a large sheet of plywood and the center of gravity with the fence all the way to the right. Maybe it's ok, maybe not. I would support it. You could just stick a 2x4 under it when you need the support.

I think you can get a new mobile base for not very much money. Or you can do what i'm going to do so you don't need any of that.

You can get a melamine 4x8 sheet from the borg for $40, maybe less and an aluminum router plate from rockler for i think $30.
brian
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