Custom router insert - how big to make it? - Router Forums
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post #1 of 3 (permalink) Old 01-03-2010, 03:27 PM Thread Starter
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Default Custom router insert - how big to make it?

I am building a custom router table with a custom insert from a 3/8" x 12" x 12" polycarbonate blank. My Bosch router base is 6" in diameter, so I don't see any reason to make the insert any larger than about 6 1/2" x 6 1/2". Can anyone give me a reason to make it larger? It seems to me that the smaller the insert plate, the better, as long as the router can be removed through the hole in the table. What other consideration are there? Am I missing something?
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post #2 of 3 (permalink) Old 01-03-2010, 03:31 PM
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Will you be keeping the handles on the Bosch? You only really need 1/2" of ridge supporting the plate, but take cxare such a large one does not sag, I would make the plate smaller.
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post #3 of 3 (permalink) Old 01-03-2010, 03:39 PM Thread Starter
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No, since this is to be a permanent mounting more or less, there is no need to keep the handles on the router. Yes, I am concerned about the plate sagging. I don't know how rigid polycarbonate is so I am trying to reduce the chance of that.
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