Project 3 by redbeard: Telescoping Legs

This project was born from the need to add outfeed tables to my Shopsmith multipurpose woodworking tool. Since the cutting height of the table saw is adjusted by raising and lowering the table and not the blade, the outfeed extensions needed to be adjustable as well.

Technically, a welder is optional for this project, but a lathe and a full length press are required. The legs are made from 3/4" and 1" EMT with a 3/4" steel compression connector providing the locking mechanism. Note: a die cast connector WILL NOT WORK.

Attachment 3809

The key to making the legs is a custom die turned to an appropriate size to expand the connector inside the larger piece of conduit. (Pay no attention to the horrible in-a-hurry beginner machinist skills shown here.) The dimensions for the die were all made by trial and error, but measurements can be made upon request.

Attachment 3808

Make sure the conduit is cut squarely, then place the threaded end of the connector into the 1" EMT and press the die all the way through, expanding the connector into the conduit. Welding it is optional, but even after 3 years of use, does not seem to be required.

Attachment 3807

The top of the inner piece is expanded to keep it centered and prevent wobbling and unnecessary stress on the connector.

Attachment 3806

Feed the inner piece through and assemble the compression fitting.

Attachment 3805

Add a rubber tip.

Attachment 3804

Attach the top with the method of your choosing.

Attachment 3803

And voila!

Attachment 3802 Attachment 3810