If you made the top in three layers as has been suggested, with the outer layers being 1/2" plywood and the middle 3/4", you could make a sliding outrigger that was built into the top. 1/2" EMT is .708" nominal diameter, 3/4" plywood is around 23/32" (.718") so all you would need to do is glue in a thin shim of veneer/edge banding to give a "tight" fit on the OD of the EMT.
- work out where you wanted the EMT and cut the first strip to width and attach it to the bottom layer.
- place the first piece of EMT against the edge of the 3/4" strip and snug the second piece of 3/4" against the EMT to give the sliding fit you need and fasten the second piece in place.
- repeat for the second piece of EMT and fasten the final piece of 3/4" in place.
- glue the shim in the bottom of the channels and check that the thickness is correct, sand if needed
- fasten the top layer of 1/2" plywood in place and you're almost there.
- make a riser for the outer end of the EMT, height to match the outriggers on the table and attach it to the end of the EMT pieces..
This would give you a sliding outrigger that could extend past the end of the saw table, with the option to put a leg/support under the outer end if you have a lot of weight on it. If you laid out the channels correctly, the outrigger could be used at either end of the miter saw stand. You could also add a stop block to the sliding support so that multiple pieces could be cut, but would need to put a clamp mechanism to stop the outrigger from sliding - easy way would be to just set a T-nut into the top over the EMT and use a threaded knob to clamp down on it.
- work out where you wanted the EMT and cut the first strip to width and attach it to the bottom layer.
- place the first piece of EMT against the edge of the 3/4" strip and snug the second piece of 3/4" against the EMT to give the sliding fit you need and fasten the second piece in place.
- repeat for the second piece of EMT and fasten the final piece of 3/4" in place.
- glue the shim in the bottom of the channels and check that the thickness is correct, sand if needed
- fasten the top layer of 1/2" plywood in place and you're almost there.
- make a riser for the outer end of the EMT, height to match the outriggers on the table and attach it to the end of the EMT pieces..
This would give you a sliding outrigger that could extend past the end of the saw table, with the option to put a leg/support under the outer end if you have a lot of weight on it. If you laid out the channels correctly, the outrigger could be used at either end of the miter saw stand. You could also add a stop block to the sliding support so that multiple pieces could be cut, but would need to put a clamp mechanism to stop the outrigger from sliding - easy way would be to just set a T-nut into the top over the EMT and use a threaded knob to clamp down on it.
