Add router table with dust collector to your table saw - Router Forums
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post #1 of 17 (permalink) Old 05-31-2016, 05:43 PM Thread Starter
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Default Add router table with dust collector to your table saw

Recently I modified my portable table saw to replace the right extension table with a hinged router table. The hinged table design allows easy access to change router bits and adjust bit depth. The router section is also enclosed to provide dust collection and to reduce router noise.

I wrote an Instructable that provides the specifics concerning how I modified my portable Delta contractor table saw. Since table saws vary in construction details, the construction approach will need to be adjusted as necessary for other table saws.

See instructables.com for Add a router table with dust collector to your table saw

My inspiration for this tool came from Tom Clark's "Practical Shop Cabinets" (pages 36-41). He describes how to build a hinged top stand-alone router table with dust collection. I modified Tom's design for my table saw.

Tom had several design requirements for his table, including:

1) Smooth lid

2) Hinged top to enable easy access for router bit replacement & adjustment

3) Built-in dust collector

To which I added the following requirements:

4) the router table had to fit as an extension table to my table saw

5) easy removal of the router for other uses if needed

I have just put the router table into service and it appears to meet all of the above requirements.

Note: I had to modify the dust collection method so that the suction comes from the bottom in order for this to work with my shop vac.

If I were to do this again, I would use a formica top with a hardwood base (vs countertop with a particle board base) to minimize any flexing/bowing of the top.
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post #2 of 17 (permalink) Old 05-31-2016, 06:45 PM
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nicely done Paul...
but I have one question...
when you clamp the top to the fence doesn't that wrack the fence...

and welcome to the forums Paul...
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Last edited by Stick486; 05-31-2016 at 06:47 PM.
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post #3 of 17 (permalink) Old 05-31-2016, 07:49 PM Thread Starter
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The clamp only requires light pressure to hold the top up to change bits or adjust the depth. I haven't noticed any deformation of the fence. But I could use a softer clamping device ... it would be easy to make a fixed width wooden clamp.
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post #4 of 17 (permalink) Old 05-31-2016, 08:09 PM
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Well that's much more impressive than what I conjured up for my TS . Nice work

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post #5 of 17 (permalink) Old 05-31-2016, 08:18 PM
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Thanks for the ideas Paul. It will save me three square feet of precious space. I'll probably fix the fence where it clamps to the TS fence

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post #6 of 17 (permalink) Old 06-01-2016, 05:53 AM
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Nicely done, Paul, and welcome aboard! How is the heat build-up inside the box, or have you run it long enough to know?

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post #7 of 17 (permalink) Old 06-01-2016, 06:45 AM
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Welcome to the forum, Paul. Nicely done on the the router set up.

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post #8 of 17 (permalink) Old 06-01-2016, 07:25 AM Thread Starter
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Difaulkner - So far I've only used the router for a few minutes at a time, with no noticeable heat build up. It's hard to see from the pics, but I've got a second small opening at the front bottom of the box that also provides some air flow at the base of the router. This design is very similar to Tom Clark's design, and he's experienced no heat buildup problems over years of heavy use.
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post #9 of 17 (permalink) Old 06-01-2016, 07:29 AM
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This looks very clever and efficient. Thanks for sharing it with us, and Welcome to our little group!

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post #10 of 17 (permalink) Old 06-01-2016, 08:02 AM
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Wow, nice execution. Looking at the design, you might consider adding a small rod to hold the lid up instead of the clamp. Something like the rod that holds up a car hood. You could hinge it or just have it set in a shallow groove under the top with a small, shallow hole under the top to set the rod in to hold the top up, No pressure on the fence that way and out of the way otherwise.

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