Extend'a'Table - Router Forums
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post #1 of 14 (permalink) Old 11-20-2019, 09:38 PM Thread Starter
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Default Extend'a'Table

Today I finished building extensions to my router table.

As you can see in the photos, the router table is a benchtop Bosch table. It is sturdy and convenient, but has a very small top (about 25” x 16”). I mounted it on an old nightstand, to which I added casters so it can move around my workshop (when it’s in the mood…). Although the table has a good fence, the maximum distance between the bit and the fence is only about 3”. I already modified the table by adding T-tracks for the fence bolts instead of the slots in the top it came with.

Usually, I route small pieces. I mostly make toys and models, sometime boxes. However, I have plans for some “large scale” work: building a special cabinet for my wife’s glass raw materials. She’s an artist, and is focusing now on glass mosaics. Her raw materials are glass plates, ranging in size from 8” x 8” to 14” x 14”. In order for them to be stored safely so that each plate can be visible and easily pulled out, and organized by colors, and (most important!) kept away from my 1-year old granddaughter who is able to get everywhere and climb anywhere, I designed a special cabinet. But I digress…

To build this cabinet I need to cut quite a few dados and rabbets, and I don’t have a dado blade for my table saw. Also, my table saw is a benchtop one (DeWalt DWE7490X) and its top is relatively small. Some dados and rabbets I can cut using a hand-held router and a jig, but my router is too heavy for me to handle without the risk of straying (It’s a Bosch MRC23EVSK). One may ask: considering the amount of work you put into the extensions (yes, I’ll get to them shortly…), why wouldn’t you just buy a dado blade? A fair question, to which I don’t have a good answer, except that I like challenges and I also expected the project to be simpler… (is anyone surprised?...)

Since in the past I had to struggle with routing long pieces (mostly for frames for my wife’s mosaics), I decided to also “widen” the table.

So I built one back extension, adding 16” to the back of the table and allowing a distance of 18” between the bit and the fence (which may be unsafe!), and two side extensions adding 20” on each side. The back extension has T-Tracks to match those I added to the table. All extensions are removable (fastened to the table with brackets and knobbed bolts), so I can remove them when not in use. It takes about 8 minutes to install all extensions, but I’m sure I’ll get better at it with practice…

Here is another good question one may ask: why not just build a new table, or alternatively get a sheet of plywood, cut a hole for the router lift and bolt the plywood to the top of the table? I do have an answer to that: I wanted the extensions to be removable (particularly the back one) because I don’t have enough space in my shop for a large permanent table, and I only need the extensions occasionally. I can also choose to install only the side extensions or only the back one as needed.

The design focused on strength and durability. As you can see, the back extension can carry a small dog (11lbs). Don’t worry – the router was unplugged for this demonstration… My little Maggie was not particularly happy, but she was easily appeased with a treat after the photo shoot… The tops of the extensions are old leftover countertops (laminated particle board) which I chose in order to get a smoother surface. The supports are 3/4” plywood from offcuts in the shop. Even the hardware (screws, brackets, knobs) where laying around in the shop. No expense spared…

I also added the Sketchup design. I’ll gladly share the file with anyone who might be interested (although I expect measurements will need to be adjusted for specific router tables).
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One year of experience repeated 10 times is not 10 years of experience.
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post #2 of 14 (permalink) Old 11-21-2019, 10:15 AM
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The dog does not look happy.
Stick486 and RainMan 2.0 like this.

When the enemy is in range, so are you.
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post #3 of 14 (permalink) Old 11-21-2019, 12:13 PM Thread Starter
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No, she wasn't... But as I said in the post she got over it quickly when she got a treat...

One year of experience repeated 10 times is not 10 years of experience.
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post #4 of 14 (permalink) Old 11-21-2019, 12:49 PM
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That's a well executed solution...
I like it...

This would have been the week that I'd have finished chewing thru the restraints...
If only new layers hadn't been added....

Stick....
Forget the primal scream, just ROAR!!!
"SNORK Mountain Congressional Library and Taxidermy”
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post #5 of 14 (permalink) Old 11-21-2019, 12:50 PM
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Quote:
Originally Posted by Bushwhacker View Post
The dog does not look happy.
looks more like suspicious to me...
RainMan 2.0 likes this.

This would have been the week that I'd have finished chewing thru the restraints...
If only new layers hadn't been added....

Stick....
Forget the primal scream, just ROAR!!!
"SNORK Mountain Congressional Library and Taxidermy”
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post #6 of 14 (permalink) Old 11-21-2019, 03:29 PM Thread Starter
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Quote:
Originally Posted by Stick486 View Post
looks more like suspicious to me...
How would you feel sitting on a tiny platform 10 times your height above ground with no rails?... I would ask: "How the heck did I get here and how can I get back down to earth...?"
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One year of experience repeated 10 times is not 10 years of experience.
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post #7 of 14 (permalink) Old 11-21-2019, 03:34 PM
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Quote:
Originally Posted by OldCurmudgeon View Post
How would you feel sitting on a tiny platform 10 times your height above ground with no rails?... I would ask: "How the heck did I get here and how can I get back down to earth...?"
or... NOW WHAT!?!?! ....

This would have been the week that I'd have finished chewing thru the restraints...
If only new layers hadn't been added....

Stick....
Forget the primal scream, just ROAR!!!
"SNORK Mountain Congressional Library and Taxidermy”
Stick486 is online now  
post #8 of 14 (permalink) Old 11-21-2019, 03:39 PM
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Quote:
Originally Posted by Stick486 View Post
or... NOW WHAT!?!?! ....
Don't you dare turn that thing on!!!

HJ

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I took the tests and retirement is the best job I'm suited for.

Now I know why old guys wear suspenders.
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post #9 of 14 (permalink) Old 11-21-2019, 03:40 PM
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Sometimes it's a challenge just to prove you can do it!!

HJ

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I took the tests and retirement is the best job I'm suited for.

Now I know why old guys wear suspenders.
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post #10 of 14 (permalink) Old 11-21-2019, 07:14 PM
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Very nice...!

Repurposing is a beautiful thing...!

Nick

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
GIVE A MAN A FISH and you feed him for a day.
TEACH HIM HOW TO FISH and you feed him for his life time.
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