

I needed some outfeed rollers for my table saw and I also wanted to use them for my horizontal band saw and my compound miter saw.  My brother-in-law gave me alot of 1/2" x 1-1/2" x 1/16" rectangular steel that he got from the local mall when he worked there.  The steel was used for some kind of shelving display. I also bought 24 rollers off of ebay for $3.00 each, 10 are 20" and 14 are 16" so the cost for these were $95.00.  I also had 48 feet of 1-1/2" x 1-1/2" x 1/8" square tube that I bought for a different project but decided it was too heavy.  I acutally wanted 1" x 1" x 1/16" but the local supplier couldn't get it and ordered the larger metal instead.  This metal would of made my portable compound miter saw stand not very portable. ![]() The rectangular steel for the frames is 4 feet long.  I drilled 5 equal spaced 1/2" holes starting from 2-1/2" from each end for the roller axles to fit in to.  After I welded the frames I noticed that they flexed from side to side enough for the middle rollers to fall out of. This was solved by welding a 1/16" x 1" steel bar to tie the two frame rails together next to the middle roller. ![]() Next I took some 2" x 2" x 1/8" angle steel and cut off 16 pieces 4-1/2" long. Then I took 16 pieces of angle steel and cut it down to slightly over 1-1/2" x 1-1/2" x 3" to form the outer side of the leg sockets, I placed a section of the leg metal between the two and welded the angles together, then to the roller frames. ![]() ![]() For the legs I thought about making them foldable, but if I did this it would add to the cost and I would have to make bracing to keep the legs from collapsing.  This is when I came up with the socket idea.  The legs are 33" long x 1-1/2" x 1-1/2" square tube. I cut 16 pieces of 3/4"-10 all thread 6" long. Took the nut and a washer and welded them to one end of the all thread. Placed a 3/4"-10 nut into the leg tube and welded them in place. ![]() ![]() |