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The buzz around the woodworking community is undeniable: the Bow XT Extender Fence System is everywhere, and it promises to revolutionize how you use your table saw. But is it truly worth the hype and price tag? While the professionally manufactured system offers notable benefits, a homemade version might be a more accessible and cost-effective solution for many DIY enthusiasts. This guide breaks down how one creator built their own fence extension from scrap plywood and affordable hardware, offering an in-depth look at the process, challenges, and final results.
Key Takeaways
- DIY Alternatives Save Money: The Bow XT Extender Fence System costs upwards of $300, but with basic tools, plywood, and hardware, you can build your own for a fraction of the cost.
- Custom Dimensions Are Possible: The homemade version allows you to adjust the size and features to fit your specific needs.
- Skill Development: Building your own tools offers an opportunity to refine your woodworking skills and gain confidence in problem-solving.
- Safety Remains Key: Regardless of enhancements, proper table saw techniques are irreplaceable for avoiding accidents.
Crafting the Fence Extension
Materials and Design
The creator started by using leftover plywood, highlighting how accessible materials can yield professional results. To mimic the Bow XT Extender, they designed their extension slightly larger at 48 inches long and 5.5 inches tall. Doubling the plywood’s thickness added durability and allowed for routed channels to hold hardware securely.
Adding T-Tracks
T-Tracks are essential for attaching accessories like featherboards. The guide outlines two methods:
- Buy Pre-Made Tracks: While effective, longer tracks can be costly.
- Route Your Own: A $10 T-slot router bit enables you to cut tracks into the plywood, saving money and providing flexibility.
Attaching to the Fence
Rather than using the Bow XT’s proprietary clamps, the creator opted for toggle clamps. These are affordable, easy to use, and compatible with the existing table saw fence.
Enhancements
- Infeed and Outfeed Supports: Simple rectangles of plywood with T-track bolts allow for easy attachment and removal.
- Featherboards: Purchased for convenience, these enhance safety and precision when cutting.
- Blade Guard: Made from plexiglass, the DIY blade guard adds an extra layer of protection.
Finishing Touches
Polyurethane and wax provided a smooth and durable finish, while creative touches like sanding edges and filling flaws elevated the overall appearance.
Challenges and Improvements
Though functional, the DIY fence extension wasn’t without issues:
- The blade guard design restricted certain cuts.
- Some aesthetic imperfections remained despite efforts to hide them.
- Adjustments, like enabling lateral movement for the blade guard, would improve the design.
Comparing to the Bow XT Extender
The Bow XT Extender is a polished, ready-to-use product designed with precision. However, for those with more time than money, a DIY option like this one offers comparable functionality. For others, the Bow XT Extender might be worth the investment.
This DIY table saw fence extension exemplifies the ingenuity and resourcefulness of the woodworking community. Whether you choose to build your own or invest in a commercial product, the ultimate goal is the same: improving safety, precision, and efficiency in your workshop. If you’re ready to take on the challenge, grab some scrap plywood, fire up your tools, and create a customized solution that works for you.