Assembly Table Build - Router Forums
 6Likes
Reply
 
LinkBack Thread Tools Display Modes
post #1 of 13 (permalink) Old 09-28-2020, 11:16 AM Thread Starter
Registered User
 
Join Date: Jul 2012
Country: United States
First Name: Gary
Posts: 806
 
Default Assembly Table Build

My Son made this assembly table (based loosely on the Ron Paulk design) with an add on swing up side to load large sheets of plywood. The upper section was made using 3/4" birch plywood. The basic bench size is 30"x 60" and has a swing up loading leaf that adds about 29".

He now wants to make dog holes into the top at 4" spacing in both directions using a 3/4" spiral router bit in a plunge router. The dog holes will perforate the complete top (similar to the Festool type top). I would like to know if any members here have made a jig to make repeatable holes to accomplish this, and how you did it. We don't have access to any machine shops to make any drilling jig and would like to make a jig from plywood to accomplish this. Any Ideas would be appreciated.
Attached Thumbnails
Click image for larger version

Name:	20200922_170657.jpg
Views:	46
Size:	1.18 MB
ID:	393235  

Click image for larger version

Name:	20200922_141828.jpg
Views:	45
Size:	1.07 MB
ID:	393237  

Click image for larger version

Name:	20200924_Assy Bench.jpg
Views:	45
Size:	959.4 KB
ID:	393239  


Woodworking is like wetting myself...Only I know that warm feeling!
gmercer_48083 is offline  
Sponsored Links
Advertisement
 
post #2 of 13 (permalink) Old 09-28-2020, 01:12 PM
Registered User
 
JOAT's Avatar
 
Join Date: Apr 2010
Country: United States
First Name: Theo
Posts: 6,843
 
Default

Quote:
Originally Posted by gmercer_48083 View Post
He now wants to make dog holes into the top at 4" spacing in both directions using a 3/4" spiral router bit in a plunge router. The dog holes will perforate the complete top (similar to the Festool type top). I would like to know if any members here have made a jig to make repeatable holes to accomplish this, and how you did it. We don't have access to any machine shops to make any drilling jig and would like to make a jig from plywood to accomplish this. Any Ideas would be appreciated.
I'd just lay out lines at 4" intervals, going both ways, then drill the holes where the lines crossed.
Herb Stoops likes this.

"It ain't what you're told, it's what you know." - Granny Weatherwax
Fawkahwe tribal police SWAT Team
Some days, the supply of available curse words is insufficient to meet my demands.
.....Call me a craftsman, artisan, or artistic, and I will accept that. Call me an artist and you will likely get a quite rude comment in return. I am not a @#$%ing artist.
JOAT is online now  
post #3 of 13 (permalink) Old 09-28-2020, 01:22 PM
Forum Contributor
 
Join Date: Oct 2014
Country: United States
Posts: 8,943
 
Default

I just laid mine out and drilled them.
Herb
Herb Stoops is offline  
Sponsored Links
Advertisement
 
post #4 of 13 (permalink) Old 09-28-2020, 02:04 PM Thread Starter
Registered User
 
Join Date: Jul 2012
Country: United States
First Name: Gary
Posts: 806
 
Default

Multiple cauls will be used to to support sheet plywood above the bench to cut them using a track saw. The cauls may be various lengths and will have pegs that locate them into the bench. For the pegs (in the cauls) to line up at different locations, the hole spacing must be as accurate as possible, and repeatable. The cauls will be removed when not using and stored so the bench can be used as a normal bench... or individual dogs or clamps can be added as necessary when needed. If the bench used just individual dogs the accuracy probably wouldn't matter, but since the cauls (long boards with pegs) are used... it would be nice to have the pegs align wherever needed on the bench and not only to the two holes that happen to line up.
Herb Stoops likes this.

Woodworking is like wetting myself...Only I know that warm feeling!

Last edited by gmercer_48083; 09-28-2020 at 02:12 PM.
gmercer_48083 is offline  
post #5 of 13 (permalink) Old 09-28-2020, 03:28 PM
Registered User
 
Nick2727's Avatar
 
Join Date: Aug 2020
Country: Canada
First Name: Nick
Posts: 17
 
Default

https://www.leevalley.com/en-ca/shop...-hole-bushings

theres a 45 second video on the page showing how they mounted the bushing to what looks to be plywood and hardwood scraps.

maybe something like this could help? have different sized plywood spacers for the different rows?
Nick2727 is offline  
post #6 of 13 (permalink) Old 09-29-2020, 12:42 AM
Registered User
 
MEBCWD's Avatar
 
Join Date: Jan 2012
Country: United States
First Name: Mike
Posts: 3,696
 
Default

You might check to see if there is anyone local that has a CNC that could cut you a template. You would need to make sure they know what you are doing and what size bushing you want to use.

It should be easy to layout in the design software and easy to cut on the CNC.

Where are you located?

Mike
Your BRAIN Is The Most Important Power Tool In Your Shop. Turn It On Before You Turn On Any Other Power Tool.
A Disability Is Only A Disability If You Let It Be One

Last edited by MEBCWD; 09-29-2020 at 12:48 AM.
MEBCWD is offline  
post #7 of 13 (permalink) Old 09-29-2020, 08:47 AM
Registered User
 
Join Date: Mar 2013
Country: South Africa
First Name: Biagio
Posts: 528
 
Send a message via Skype™ to Biagio
Default

@gmercer_48083 ,
Gary, I was planning to use the LV bushings Nick2727 referenced, but with lockdown my Canadian friends who normally visit, were unable to do so and bring the goodies out for me.

My idea was to use a four-hole jig, at the standard Festool spacing, and make two of the holes large enough for the bushings. Then mount a fence underneath, to drill the first row of holes parallel to the front of the table/bench. Thereafter the fence can be removed, and two dogs (tight-fitting) can be used as positioners in the first row, to drill two holes at a time. That way, the spacing is constant in both directions, without the jig being able to rotate off square.
LV sells a drill bit matched to the OD of the bushings, and I think one for the ID as well. I planned to use a drill rather than a router - faster, possibly less messy.

Oh well, when lockdown ends.
Biagio is offline  
post #8 of 13 (permalink) Old 09-29-2020, 09:28 AM Thread Starter
Registered User
 
Join Date: Jul 2012
Country: United States
First Name: Gary
Posts: 806
 
Default

Quote:
Originally Posted by MEBCWD View Post
You might check to see if there is anyone local that has a CNC that could cut you a template. You would need to make sure they know what you are doing and what size bushing you want to use.

It should be easy to layout in the design software and easy to cut on the CNC.

Where are you located?
I am in Troy Michigan

Woodworking is like wetting myself...Only I know that warm feeling!
gmercer_48083 is offline  
post #9 of 13 (permalink) Old 09-29-2020, 09:49 AM Thread Starter
Registered User
 
Join Date: Jul 2012
Country: United States
First Name: Gary
Posts: 806
 
Default

Quote:
Originally Posted by Biagio View Post
@gmercer_48083 ,
Gary, I was planning to use the LV bushings Nick2727 referenced, but with lockdown my Canadian friends who normally visit, were unable to do so and bring the goodies out for me.

My idea was to use a four-hole jig, at the standard Festool spacing, and make two of the holes large enough for the bushings. Then mount a fence underneath, to drill the first row of holes parallel to the front of the table/bench. Thereafter the fence can be removed, and two dogs (tight-fitting) can be used as positioners in the first row, to drill two holes at a time. That way, the spacing is constant in both directions, without the jig being able to rotate off square.
LV sells a drill bit matched to the OD of the bushings, and I think one for the ID as well. I planned to use a drill rather than a router - faster, possibly less messy.

Oh well, when lockdown ends.
I am considering a full length (60") 2 rows of 1" hole Jig to use with a 3/4" pc bushing and a 1/2" upcut spiral bit. This way to get 3/4" dog holes. Once the first row is routed into the bench, I can pin the jig to the first row of holes of the jig to the bench and do the second row... and progressively work across the bench.

Making the jig accurately is the most difficult part. To make the jig I would have to drill the holes with my drill press using another jig using pins and a guide fence to get the spacing right.

At least, this is my thought process for now.

Woodworking is like wetting myself...Only I know that warm feeling!
gmercer_48083 is offline  
post #10 of 13 (permalink) Old 09-29-2020, 10:09 AM
Registered User
 
Join Date: Mar 2013
Country: South Africa
First Name: Biagio
Posts: 528
 
Send a message via Skype™ to Biagio
Default

The difficulty you mention is the reason I thought of the 4-hole jig - much easier to get accuracy over 4 holes than over the 60" you envisage. Otherwise the idea is the same. With the first row laid out parallel to the front edge of the table (by the underslung fence), the next row will automatically be parallel to the first
Biagio is offline  
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Router Forums forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in











Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome