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Step 1. Cut hinges
The casters should NOT rest directly on the wood.
I want to use a metal based that would fit onto the bottom of the legs, and would accept the caster's bolt. However, I couldn't find anything at the hardware store. So, I made these out of outdoor 3" fence hinges
Using a metal grinder and cutoff blade and a heavy duty bench clamp, cutoff the unused portion of the hinge
I wear a leather glove on one hand
Hinges Uncut and cut
Needed Piece for Caster base
Step 2. Widen caster hole in metal base
The hole in the center of the base is not wide enough to accept the caster's bolt
I attached each base piece to a scrap of wood so it would move around
Using a metal drill bit, widen the hole so it accepts the caster
Step 3. Smooth any sharp edges
On each base plate cut from the hinge
Round the corners using a grinder wheel
Grind down the plate to match the width of the legs
Smooth over any sharp edges
Step 4. Cut hardwood base pieces
Cut five pieces of hardwood to be 6 inches in length
Sand or trim the hardwood width to match the width of the legs
Step 5. Cut notch in Support leg
In the support leg, cut a notch the same length as the hardwood (6")
The caster on the Support leg needs to move up and down to keep the table saw level, and it makes it easier to move around
Drill two 3/8" holes through the hardwood and all the way through the leg to allow a bolt to slide easily up and down (If possible use a drill press to ensure these are straight up and down)
Widen the hoel in the hardboard slightly, and pound in the gripping nuts as shown on bottom of hardwood
Step 6. Drill holes
The caster is attached to the hardwood by a a washer and a nut
Place the hardwood on the leg an drill a small hole through the hardwood and into the leg
Using a 1-1/2" spade bit drill a shallow hole for the washers in each leg
Drill a larger hole in the legs to accept the nut
Put the caster's bolt through the metal plate base and through the hardwood
Add a washer and a nut to the caster's bolt and tighten
Put glue on the hardwood that attaches to the front and back legs, but not to the Support leg
For the front and back legs attach the hard wood to the legs using long screws that go through the metal plate, and then through hardwood and about an inch into the legs
The Support leg must use shorter screws that do not go all the way through the hardwood
Tighten the screws and with a damp cloth wipe off any excess glue
Step 7. Final
When finished with these steps, the front and back legs should look like the bottom caster on the left
The support leg should look like the top caster
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