Go to a step down in a saw to get a router table extension that matches? LOL. Not going to happen. I'm set on the functionality of the TSS. I've gone years with Cabinet Saws, using sleds and other jigs to expand functionality to what this saw does out of the box, with the accuracy I want.
Of the tools I require and their use in order- (1) Sliding Compound Miter Saw, (2) Table Saw and (3) Router Table. I'm not currently working full-time as a carpenter, so I see the table saw use going up in my ranks. Woodworking helps me unwind, relax and get my head straight.
Why add a Router Table Extension to this Saw? The saw's footprint is large and I have limited work space. My current shop saw has a large footprint, but this saw is larger- not just in size, but how the infeed and outfeed goes.
I looked at this company's 5 function combo machine (TS, shaper, jointer, planer, mortiser... but it had twice the footprint. I saw problems going from one function to another that sacrificed form, function and time. I didn't like how it was laid out and it seemed I would have to make concessions and workarounds to use each function. (and it was 3-phase) Space is an issue with me. Like some other members here, I often have to move stuff out of the garage to work seriously.
I already have 3 router tables, which I hope to replace at least 1 table with an extension wing... And later build a horizontal table to replace one of the others. On the extension, I can use many of the fences and other accessories from the table it's replacing.
On this planned router extension... I could make it one piece in wood. But besides woodworking, I have experience with welding/fabrication and machining. Whatever I do, I will make it look clean and professional. I want to keep the lines of the saw and in the same style of the saw. If I add 2 inches on each side of the cast iron extension and wrap around the end to add another 8" or so to the router table, that it would look more professional and be more usable to me. Like I said, I don't want to step down by losing function.
I looked at the Bench Dog's and Grizzly's cast iron router extensions (same size). I didn't like their tables and fences.
I could add on to a standard sized TS router table extension and make it the same size easily by just using some 2" extruded aluminum on each side of the extension. But I also thought about using aluminum plate or stainless.
I don't plan on just hanging something off the end... I want to to be sturdy and last. Weight of the extension and any needed bracing is not an issue as the saw itself is already over 1000 pounds. I plan on making it look good. Most importantly, it needs to be as functional or more so than what I already have.
I toyed with the idea of morphing in a shaper table instead of a router table extension... but I love working with router tables.