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Add a removable outfeed roller to a wooden sawhorse with two sliding conduit posts, adjustable conduit hangers, elbows and a PVC sleeve. The posts guide the roller assembly while the hangers set its height. The design below is based on WOOD Magazine’s project; it has no published load rating, so treat it as an adaptable shop aid rather than a rated support.
How the sawhorse roller works
WOOD Magazine contributor Dave Baer describes needing extra support for long cedar deck boards exiting a table saw when his sawhorses were too short or obstructed the boards’ path. His design adds two vertical electrical-conduit posts to a wooden sawhorse and joins them with a crosspiece sleeved in PVC. The post guides let the roller height be adjusted, and the assembly can be removed and rested on the sawhorse’s cross braces when not in use. Read the WOOD Magazine project.
Materials and fit
- Two pieces of 1/2-inch electrical conduit for the side posts.
- Two conduit hangers with wing nuts for setting post height.
- Two wood-screw-type eyebolts sized so the conduit can pass through their eyes.
- Two 1/2-inch conduit elbows.
- A length of 1/2-inch conduit for the crosspiece.
- 1-inch PVC pipe to sleeve over the crosspiece and form the roller.
Match the fittings and fasteners to the sawhorse you have. The source specifies the conduit and PVC sizes but does not establish minimum sawhorse dimensions or a universal cut list.
Build and adjust the roller
- Cut the posts. Cut two pieces of 1/2-inch conduit a little shorter than the sawhorse’s height.
- Fit the height hangers. Install one conduit hanger low on each end of the sawhorse. The hangers support the posts and let you set the roller height; wing nuts make adjustment easier.
- Add the post guides. Screw one wood-screw-type eyebolt into the top brace at each end of the sawhorse. Check that each eye is large enough for its conduit post to move through it.
- Attach the elbows. Fit a 1/2-inch conduit elbow to the top of each post.
- Measure the crosspiece. Measure between the ends of the elbows and add 1 inch. Cut the crosspiece conduit to that total length.
- Make the roller sleeve. Slip 1-inch PVC pipe over the crosspiece. The conduit crosspiece supports the sleeve, which serves as the roller surface.
- Set the working height. Place the posts through the eyebolt guides and into the lower hangers. Adjust the hangers until the roller meets the stock’s path. The wing nuts can also help compensate for uneven ground.
Before feeding material, check that both posts are seated, the roller turns freely and the stock travels without catching on the sawhorse. This is a practical fit check, not a load or stability test.
#1 Best Overall
- Adjustable Height From 27-In To 43-In
- Highly Visible Edge Guides Keep Work In Place
- Eccentric Foot Keeps Stand Stabilized On Uneven Surfaces
- Portable, Light-Weight Design Folds For Convenient Storage
- Trusted Quality : Manufactured by a globally recognized tool supplier, ensuring consistent performance and reliability
What this homemade design does not establish
WOOD Magazine’s description gives no rated load, tested stability result or safety certification for the homemade assembly. Its example involving long cedar boards is project context, not evidence that the build is suitable for a specific saw, workpiece or operation. Do not assign it a capacity or rely on it as a rated support. If the work requires a known load rating, use a product with published specifications for the exact configuration and follow its instructions.
Alternatives when a conduit-post roller is not the right fit
Insert that fits a sawhorse slot
A Kreg-hosted plan credited to Pneumatic Addict includes an optional hardwood-and-PVC roller insert measuring 3-1/2 by 28-1/2 inches. It also offers separate pointed-dowel and inset ball-bearing-caster inserts for other support tasks; those are distinct options, not components of the conduit-post design. See the Kreg-hosted plan.
Rank #2
- Unwavering Support for Your Projects: With VEVOR's roller stand, experience rock-solid stability that can handle heavy loads up to 2500 pounds. Trust it for your most demanding tasks.
- Adjustable Height for All: Easily customize the outfeed roller stand's height from 27.6 to 52 inches, making it suitable for workers of all heights and various applications.
- Versatile Applications: From table saws to planers and sanders, this tool stand excels in supporting your tools and materials. Whether you're working with long steel pieces, pipes, or wooden boards, count on it to provide steadfast support.
- Built to Last: Crafted from robust #45 steel, VEVOR roller stand is engineered for durability, ensuring consistent performance over the long run, no matter the wear and tear.
- Easy Folding for Space-Saving: When not in use, simply unlock and fold the support base, allowing for compact storage in a corner. Free up valuable space in your workshop while having the reliability you need.
Clamp-on roller support
National AgrAbility lists a Rockler-supplied clamp-on support for a sawhorse or workbench. Its listing specifies a 1½-by-17-inch steel ball-bearing roller, 90-degree rotation, up to 11 inches of side-to-side travel, and adjustment from 3 to 15 inches above the table. The listing’s $50 price was last updated August 19, 2024, so check the current listing for price and availability. View the National AgrAbility listing.
Freestanding roller or multi-support stand
For a stand that does not mount to the sawhorse, Grizzly lists a multi-functional product with cylindrical-roller, roller-ball and V-roller setups. Its approximate height range is 28 to 47 inches. The manufacturer lists capacities of 220 pounds for the cylindrical roller, 99 pounds for the V-roller and 440 pounds with the flat sawhorse top; those ratings apply to the stated product configurations, not to the homemade assembly. Check Grizzly’s product specifications.
Rank #3
- Rock-Solid Construction: Crafted from chrome-plated steel, this roller stand is built to last. It supports up to 250 lbs, making it ideal for easily handling heavy-duty materials during cutting and other tasks. Let’s experience smooth and secure cutting!
- Flexible Height Adjustment: Featuring a telescoping rod, our roller stand allows you to adjust the height from 27 to 43 inches, ensuring flexibility and adaptability to your project’s requirements.
- Smoothly Polished Roller Head: The 11.5-inch polished steel roller enables smooth forward and backward material movement, enhancing precision and efficiency in your work. Handle larger pieces with confidence!
- User-friendly & Folding: Carry it wherever you go! Our roller stand folds and unfolds quickly for convenient transport and storage, making it ideal for busy workshops and on-the-go tasks. It takes up minimal space for everyday storage.
- Installation Made Easy: With a simple structure and clearly labeled components, our table saw roller stand assembles in minutes, making it an ideal choice for handling long materials and cutting with ease.
Bosch’s UK product page for the PTA 1000 lists a support-height range of 700–1,150 mm and a 100 kg maximum load. It describes roller support for feeding material lengthwise and ball support for moving it in different directions. These are specifications for that product as listed on the UK page. See Bosch’s UK PTA 1000 page.
Independent reader supportYour contribution helps us test, update, and keep practical guides available for everyone.Choose support to match the work
Compare how the support attaches, how it adjusts and how the workpiece needs to move. A sawhorse-mounted design keeps the support with the horse; a clamp-on unit can be moved between compatible surfaces; a freestanding stand avoids mounting hardware on the sawhorse. A roller suits lengthwise feeding, while ball or V-style supports serve different movement or stock-shape needs. Consider storage and, where a capacity matters, verify the rating for the exact product and configuration.
Quick Recap
Best Value
- Rock-Solid Construction: This roller stand is made from chrome-plated steel, ensuring exceptional durability and strength. With a maximum load capacity of 300 lbs, it is designed to effortlessly support the cutting of heavy materials. Let’s experience smooth and secure cutting!
- Flexible Height Adjustment: Featuring a built-in telescoping rod, the stand allows users to effortlessly adjust the height from 26.8-42.5 in, ensuring flexibility during use. The adaptability enhances the overall user experience, allowing for seamless customization based on individual preferences and project requirements.
- 3-in-1 Roller Head: This design incorporates an 11.5-inch polished steel roller head along with multi-directional ball rollers, ensuring smooth transportation of materials while providing versatile support options. This functionality allows users to adapt to various project needs effortlessly, enhancing overall efficiency.
- User-friendly & Folding: Carry it wherever you go! Our roller stand folds and unfolds quickly for convenient transport and storage, making it ideal for busy workshops and on-the-go tasks. It takes up minimal space for everyday storage.
- Installation Made Easy: With a simple structure and clearly labeled components, our table saw roller stand assembles in minutes, making it an ideal choice for handling long materials and cutting with ease.
Rank #4
- Rock-Solid Construction: This roller stand is made from chrome-plated steel, ensuring exceptional durability and strength. With a maximum load capacity of 440 lbs, it is designed to effortlessly support the cutting of heavy materials. Let’s experience smooth and secure cutting!
- Flexible Height Adjustment: Featuring a built-in telescoping rod, the stand allows users to effortlessly adjust the height from 30-50 in, ensuring flexibility during use. The adaptability enhances the overall user experience, allowing for seamless customization based on individual preferences and project requirements.
- All-in-One Functionality: This multi-functional roller stand combines the features of a roller rack, log cutting stand, V-shaped rollers, multi-directional rollers, and tool storage. It enables flexible movement of woodworking outfeed while providing convenient storage for tools.
- User-friendly & Folding: Carry it wherever you go! Our roller stand folds and unfolds quickly for convenient transport and storage, making it ideal for busy workshops and on-the-go tasks. It takes up minimal space for everyday storage.
- Installation Made Easy: With a simple structure and clearly labeled components, our table saw roller stand assembles in minutes, making it an ideal choice for handling long materials and cutting with ease.
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