Router Table Insert for Bosch 4100 Table Saw - Router Forums
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post #1 of 23 (permalink) Old 07-15-2012, 06:27 PM Thread Starter
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Default Router Table Insert for Bosch 4100 Table Saw

Hi All,

I have designed a router table insert for the table extension my Bosch 4100 Table Saw. It is heavily based on John White's design (FWW), but customized for the Bosch. My design has the dust port in the fence, so it only extracts dust from the top (No room in the bottom for a dust port). The router plate is Incra, but the Woodpecker and Bench Dog plates should also fit. Everything built from 3/4" (0.71") birch plywood scraps. The frame supports the plate dado on all for sides. The fence probably has too many ribs, but I wanted each clamp slot to be supported on two sides. Please let me know what you think!
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post #2 of 23 (permalink) Old 07-15-2012, 06:40 PM
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HI Henk.

Welcome to the forum.

Is that a 9" wide fence next to the top? (I am not good at reading plans??)

James
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post #3 of 23 (permalink) Old 07-15-2012, 06:46 PM Thread Starter
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HI Henk.

Welcome to the forum.

Is that a 9" wide fence next to the top? (I am not good at reading plans??)
Hi James. That's correct. It's actually slightly wider since 9" is the width of the ribs, so the width of the front and back sub-fences and fence face is not included. The fence structure is clamped to the table saw fence with the four slots you see in the back sub-fence.
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post #4 of 23 (permalink) Old 07-15-2012, 10:33 PM
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I like it but I'm biased. I have a similar insert design for the Ridgid 4510. Not as reinforced below but so far it seems sturdy enough. My approach to the fence is different as I'm going to use the TS fence as a base and attach the router fence at the t-slots. I don't think that would work with the Bosch fence because access to the slots on the Bosch fence is different. The Ridgid fence slots extend to and are open to the end of the fence. Of course my plan may be a bust. I won't know till I finish it.

GCG
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post #5 of 23 (permalink) Old 07-15-2012, 10:54 PM Thread Starter
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I like it but I'm biased. I have a similar insert design for the Ridgid 4510. Not as reinforced below but so far it seems sturdy enough. My approach to the fence is different as I'm going to use the TS fence as a base and attach the router fence at the t-slots. I don't think that would work with the Bosch fence because access to the slots on the Bosch fence is different. The Ridgid fence slots extend to and are open to the end of the fence. Of course my plan may be a bust. I won't know till I finish it.

GCG
Hi GCG,

I'm also using the TS fence as a base. In my case I'm clamping to the TS fence (see slots in diagram). Your idea of using the t-slots makes me rethink this though, since the t-slots on the Bosch does actually go all the way through. The reason for the ribs in the fence structure is to allow the router fence to get to the bit, since the router table top wont allow the TS fence to get all the way to the bit. It also houses the dust box. Thanks for the pointers.
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post #6 of 23 (permalink) Old 07-16-2012, 05:31 AM
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Here's the thread on my insert and fence.

http://www.routerforums.com/table-mo...table-saw.html

GCG
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post #7 of 23 (permalink) Old 07-25-2012, 04:59 PM
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Looks nice. Some of the dimensions are unclear though. I'm thinking about getting that TS and have wondered about adding a router table insert. Have you built this yet?
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post #8 of 23 (permalink) Old 07-30-2012, 03:02 AM Thread Starter
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Looks nice. Some of the dimensions are unclear though. I'm thinking about getting that TS and have wondered about adding a router table insert. Have you built this yet?
Hi. I built the table this weekend, but I think I'm going to scrap my efforts. The table top sagged too much, despite the frame. I think its because the original piece of plywood had a bow in it. I thought the frame would pull it straight, but alas... I'm rebuilding this time with two pieces of ply glued together for the top, and I might add some formica if I can find a scrap piece. Will update again as I go along.
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post #9 of 23 (permalink) Old 07-30-2012, 01:31 PM
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Looking forward to hearing how it went.
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post #10 of 23 (permalink) Old 08-20-2012, 05:07 PM
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I recently purchased this same TS and the Bosch 1617 EVSPK router. Last weekend, I finished my "Router Table Insert", which was basically a piece of 3/4" shelving which I had laying around. Thus far, it is not bowing under the weight of the router, and the Gravity Lift seems very stable.

For the fence, I have just built a fence which is clamped to the saw's fence, so I can move it relatively easily and use the saws fence lock to lock it in place.

Since I am just getting started, I have tried to abide by the KISS rule since I have very little clue about what I am doing, so I do not know what features I even want to build into the parts yet.

Once I have my 10 posts, I will get some pictures taken and posted.
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