Router Table-saw Extension Underway - Router Forums
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post #1 of 42 (permalink) Old 03-10-2020, 07:44 PM Thread Starter
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Default Router Table-saw Extension Underway

I have set out to replace my 25 year +/- table saw extension with a larger and flatter one.

Using materials on hand (including left over laminate from the original it replaces) I have cobbled together this new one you see in the pictures.

The substrate is (3) layers of 1/2” Baltic birch glued and screwed. Both top and bottom are covered with laminate.

In another post I shared that I now have a Woodpecker PRL-V2 lift. Using the lift plate itself as a template, I made the wooden template I used for creating the perfectly sized opening to receive the lift.

Although this extension is heavy (and solid as a rock it seems), I will be adding some additional cross-bracing beneath plus a shop made dust collection enclosure.

I have also purchased the woodpecker combination miter/accessory track to install.

By making the extension larger, I gain the ability to move the table saw fence all the way to the right and still not impact the router bit.

I will post more as work progresses.

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Last edited by mbrun; 03-10-2020 at 07:50 PM.
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post #2 of 42 (permalink) Old 03-10-2020, 07:56 PM
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that sure is some nice clean work...
Cherryville Chuck and Nickp like this.

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

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post #3 of 42 (permalink) Old 03-11-2020, 07:40 AM
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Looks great.
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post #4 of 42 (permalink) Old 03-11-2020, 02:32 PM
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You're off to a good start. looks good so far.

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post #5 of 42 (permalink) Old 03-11-2020, 06:35 PM
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Good idea, plan and work Michael. I look forward to seeing it completed.

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post #6 of 42 (permalink) Old 03-11-2020, 11:54 PM
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Looking good Michael. I tried this myself and dun goofed at the end and aborted, so maybe I’ll learn something from yours

I don’t always insulate , but when I do .
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post #7 of 42 (permalink) Old 03-12-2020, 10:10 AM
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Nice, so far. Good idea about laminating both sides.

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post #8 of 42 (permalink) Old 03-12-2020, 04:37 PM
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Very nice Michael!
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post #9 of 42 (permalink) Old 03-21-2020, 09:28 AM Thread Starter
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I have been working on cutting all the pieces to provide additional bracing below the extension. This will further help keep it flat.

I have also started working on the dust collection box for use below the router.

Nothing is attached yet, just clamped in place so I can size all the pieces before start attaching things.

I think I am going to suck the dust out the back of the box, and provide a means to bring fresh-air in to directly vent the motor. Even toying with the idea of dust evacuation near the top. We’ll see.

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post #10 of 42 (permalink) Old 03-21-2020, 11:15 AM
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Stick talked about a snorkle (Snork-le?) or tube through the bottom of the DC box, affixed to the bottom of the router. The easiest way to do this would be to mount two connectors flat to flat and run the flex tube up to the box and attached to one side of the connector, then a short length from the other side of the connector to the router's air intake. Pix is of the connector I'm suggesting. I would also consider putting some sort of filter box on the air intake, the less sawdust you send through the router, the better. Depending on brand, the connectors are $6-$10 each.

Making the tube fit on the bottom of the router could be done with aluminum duct tape, but you won't be able to remove it easily for other uses. For that you could get an oversized adapter with one side to fit your tubing, the other larger than the router base, then line the larger opening with door insulation strips to fit snug on the router. Easy to slip on and off and no tape residue.

Beautifully executed BTW.
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Last edited by DesertRatTom; 03-21-2020 at 11:18 AM.
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