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    • Outfeed/assembly table height?
      Add some adjustable levelers to it and raise it off the wheels if needed.
    • Table saw from Craig's list
      Oh yah forgot about that.  Gee tech right?  
    • Design Idea.
      I often draw pieces like this full size on a sheet of 1/4" MDF. Then you can see the proportions.  Erasing is easy with a Random orbit  sander.
    • Powermatic 2244 or supermax 2550
      All crepe rubber blocks are not the same. The very hard , heavy , dense ones last longer and clean better. The softer ones you can flex with your hands will get used up faster and take more effort to do the job. When there is a sale if they have the hard ones I stock up.  Belt sanders, osselating spindle sanders, random orbit ,drum sanders  etc. they all benefit from clean abrasive.
    • Outfeed/assembly table height?
      I actually built my table just under an 1/8 of an inch shorter then my saw table and I didn't put channels in it because I also use it as an assembly table.  My reasoning for not putting the channels in was like you it was going to be mobile,and because I use it for assembly also, AND if I was doing crosscuts on the saw with my miter gauge of a crosscut sled I didn't really need the table there to catch pieces so I could just move it back to get out of the way of the rail from the sled or miter gauge.  My table is 32 inches wide and 48 inches long and even in the event of an occasional piece of 4 X 8 material it is adequate with it being on wheels you can turn or line it up how ever you need.  I rounded over the edges of the top so even if you had a real floppy piece of material it would still ride up over the edge and onto the table instead of jamming up causing it to bind. Don't try and save money on casters, get good one. Mine are 3 inch and the kind of soft material that rolls well even over foreign objects on the floor.  When you lock them they lock both the wheel from turning and the swivel.   Some will only put locking casters on a couple of corners, I put them on all four because when you push the table around one will always end up with the locking mechanism under the table, also if you floor is a little uneven you will always have enough casters  to lock to keep it from rolling.
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