Art, my router table will be 2 pieces of ply glued together.
The top piece is 1/2" ply, with three 10x12" rectangular holes cut into it. These holes have rounded corners because I used a 3/4" straight bit. They are all the same size, because I used a template to make them. Since the bit was 3/4", the radius of the corners is 3/8".
The lower piece is 3/4" ply, also with three holes in it, but these holes are smaller than the ones in the top piece, such that when I glue the two pieces together, they will create a quasi-rabbeted edge that will support the insert plates.
So my task is to make insert plates that fit in the holes in the top with the smallest and most uniform gap around the edge as possible.
I realize it doesn't HAVE to be perfect, but I will have projects in the future where I will want a professional looking finish. And it is time for me to start learning how to get there.
Last edited by Chris Curl; 11-27-2012 at 01:46 PM.