DIY Table Saw Extension Wings

Loosen the bolts that hold the existing right-side wing to the side of the table saw's table with a socket set. Set the wing aside.

Measure the distance between the corresponding wing mounting holes on the front and rear rails. Cut two sections of 2-by-2 lumber to this length using the table saw with the saw's miter gauge. Cut two more sections of 2-by-2 to the desired width of the new extension wing minus 3 inches.

Place the four sections of 2-by-2 onto a work table, aligning them into a rectangular shape with the second pair of boards you cut in the previous step in-between the first pair of boards. Connect the boards together with a 3-inch deck screw using a power drill at each intersection to create the extension frame.

Cut a sheet of plywood to the width and length dimensions of the frame using your table saw. Mount this plywood to the frame with the sanded side facing up with a 1 1/2 inch long deck screw every 6 to 8 inches along each edge.

Measure the locations of the mounting holes on the side of the saw table and the front and rear rails, and transfer these hole locations to the edges of the extension wing frame with a pencil. Drill holes for the extension wing mounting bolts that you removed when you pulled out the small extension wing.

Position the new extension wing into place between the front and rear rails and against the right side of the saw table. Mount the extension wing to the table saw and rails using the bolts and a socket set.