Yet another router table build ... - Router Forums
Reply
 
LinkBack Thread Tools Display Modes
post #1 of 24 (permalink) Old 10-09-2014, 01:42 AM Thread Starter
Registered User
 
JohnBFisher's Avatar
 
Join Date: Sep 2014
Country: United States
First Name: John
Posts: 22
 
Default Yet another router table build ...

Greetings! Yes, I know. Everyone and their brother (or even sister) posts pictures of their router tables.

But I did have some questions about my project when I made my introductions. So, I thought I would post some of what I'm doing.

First, here are my requirements. I need this to be collapsible. And it needs to be sturdy. And it needs to be moderately inexpensive.

Why collapsible? Well, it's in our garage and I intend to continue to use it as a garage. When I'm not doing a project, the router table needs to be stowed away so TWO cars can fit in the garage.

Sturdy and moderately inexpensive are both pretty obvious. I sure don't want the final results to be anything other than very, very stable. But on the other hand, I simply can not afford a full blown table top and stand.

Ouch! Anyone know anything about project management? There's an old tale that President Truman was shown some of the problems of bring a project in on time and budge and at the quality desired. He noted that you can have any two of the three objectives (speed, cost, time), but not all three. It's known as the Truman Triangle.

Well, I just described a Truman Triangle in the wood working shop. It needs to be collapsible and sturdy and moderately inexpensive. Can you actually accomplish all three?

Yes! But you need to have the mindset of a hacker. Not a destructive individual, but someone who can take pieces not normally associated with this approach and put together a solution.

Of course, I've been working on this project for the past 20 years. No, really! I've always loved fancy joinery work. Many, many moons ago I purchased an Incra Jig. They now call it the Original Incra Jig. Well, mine is the original Original Incra Jig. But my work life overtook any spare time I might spend on it. Now that I've retired and I need some moderate activity, I decided to complete this project.

So, after a LOT of research, I decided to make my own table and stand. The table is made from a 3/4" melamine board. Yes, I know it's not as stable as it should be. So, along the long sides and the short front and back, I glued (using a polyurethane glue) and screwed 1x4 boards underneath. Melamine boards have the advantage of having a slightly pebbled surface, which improves the ability for things to slide over it. I'll use a silicone spray to enhance that slick feeling.

Along the two long sides, I routed channels for two Hart Designs Utili-Track T Tracks. This allows me to accurately measure placement of the fence from the center of the router plate. Here's this T Track:



Along the front of the table, near the router plate, I decided on a Kreg Combo Track. This provides the T Track or Miter slot, depending on the needs of the project.



And then I decided that I wanted an Incra Router Plate. I went with the plate predrilled for the DeWALT DW625 plunge router.



After doing research, I found that I could purchase a used DeWALT DW625 router, the Router Raizer, and the eXtreme eXtension and end up with essentially a router lift built into this table.

Here's a photo of a modified DW625:



Cool! If all goes well, I'll end up with a router table that will perform as well as one that cost hundreds of dollars for MUCH less.

Because the melamine board is only 3/4" thick, it needed some reinforcement under it. And to make it easier to route out the opening for the router plate, by using the Incra Clean Sweep adapter, it's possible to route the opening with a straight cut bit following the Incra router plate template. I used the Kreg Plate Levelers to help better support the plate in the corners.

Here are a couple images of the Clean Sweep adapter and the Kreg plate levelers:





Note that I cut down the bolts holding the Combo Track in place. Since this is near the front of the table, I didn't want to cut my hand reaching under the table.

And here's the router table top, mostly completed:



Unfortunately, I measured and measured and still got the measurements wrong for the combo track. I'll need to add a shim in front of the combo track. Sigh!

Here's what the Utili-Track looks like, with the rule added to it:



The T-Tracks on the side will allow me to mount the Incra Jig on a board that I can readily move and reposition. The rule in the T Track will allow me to reliably reposition it whenever I want.

Though I found lots of router legs, their problem was both expense and the fact that they were not designed to be collapsed. I finally found work table legs at the Home Depot that should fit the bill:



Additionally, they include the ability to include an outlet built into the legs:



Using a switched outlet, a small appliance cord to connect the router table to power, and a small extension cord with multiple outlets to power the router and shop vacuum, I can create a single switch to drive both my router and ShopVac:



There's still a lot more to do:
  • Cut stringers (using a piece of 1x6 and one 1x2).
  • Cut and mount the board on which I will mount the Incra Jig
  • Mount the Incra Jig
  • Add the fence to the Incra Jig
  • Fabricate and mount a dust collection box

And of course, in order to do this, I will need to modify some of my other tools to make them more accurate and usable. I will add a Drill Press Table jig. And I will add a Zero Clearance Throat Plate to my table saw.

I'll update this post as I make progress.
JohnBFisher is offline  
Sponsored Links
Advertisement
 
post #2 of 24 (permalink) Old 10-09-2014, 01:57 AM
Registered User
 
RainMan 2.0's Avatar
 
Join Date: May 2014
Country: Canada
First Name: Rick
Posts: 16,072
 
Default

Wow John thanks for sharing this build . I will be watching your progress closely as I too want a foldable router table to save on room when it's not in use . Looks like you have a great game plan so far.

John being the noob that I am , I'm not fully understanding the need for miter slots in both directions but I guess it can't hurt

I donít always insulate , but when I do .
Ok ,I never insulate

Last edited by RainMan 2.0; 10-09-2014 at 02:04 AM.
RainMan 2.0 is online now  
post #3 of 24 (permalink) Old 10-09-2014, 02:12 AM
Moderation Team
 
Semipro's Avatar
 
Join Date: Mar 2013
Country: United States
First Name: John_*
Posts: 6,468
 
Default

Well John I for one like all the pictures so post away, looks like you got a good handle on what you want.
Semipro is online now  
Sponsored Links
Advertisement
 
post #4 of 24 (permalink) Old 10-09-2014, 07:01 AM
Registered User
 
boogalee's Avatar
 
Join Date: Nov 2010
Country: United States
First Name: Al
Posts: 479
 
Default

Quote:
Originally Posted by JohnBFisher View Post
I'll use a silicone spray to enhance that slick feeling.
IMHO I would not use a silicone spray. It has the ability to mess up a finish.

Quote:
Originally Posted by JohnBFisher View Post
Using a switched outlet, a small appliance cord to connect the router table to power, and a small extension cord with multiple outlets to power the router and shop vacuum, I can create a single switch to drive both my router and ShopVac:
Dewalt 625 is rated @ 15 amps and a shop vac can be rated @ as much as 12 amps. I think a small appliance cord to be to small (wire gauge wise).

Other wise you seem to have it all together.

Al B

Last edited by boogalee; 10-09-2014 at 07:05 AM.
boogalee is offline  
post #5 of 24 (permalink) Old 10-09-2014, 10:10 AM
Registered User
 
Join Date: Oct 2009
Country: United States
First Name: Brad
Posts: 1,036
 
Default

There is a photo of a folding router table design on wheels floating around on this forum. I will look for it and post it, if I can find it.

It was a pretty slick design.

Good luck with your project and keep us posted.

And ditto on the silicone. No bueno for wood surfaces\finishes.


Just remember what my father always said, " Half the people in this world are below average!", and everything in life will make a hellova lot more sense.
timbertailor is offline  
post #6 of 24 (permalink) Old 10-09-2014, 10:43 AM Thread Starter
Registered User
 
JohnBFisher's Avatar
 
Join Date: Sep 2014
Country: United States
First Name: John
Posts: 22
 
Default

Quote:
Originally Posted by RainMan1 View Post
... John being the noob that I am , I'm not fully understanding the need for miter slots in both directions but I guess it can't hurt ...
The Miter slot (part of the Combo Track) is only along the front of the router table. The two T Tracks along the side as well as part of the Combo Track are designed to help with hold down clamps, feather boards, etc.

Additionally, since I like to have a tool do dual duty, this table will also allow me to clamp down and hold together wood projects as glued joints "set up". So, having the T Tracks along the side and front will give me a lot of versatility for holding those projects.

The Miter slot will allow me to use a miter gauge with the router. For example, if I want to create some small tapered legs for a box, it can actually be easier to use my router rather than a table saw for such small parts.



Or the miter slot can allow me to use a coping sled with the router.



Since I want to work on small boxes the ability to precisely handle the boards becomes very important.
JohnBFisher is offline  
post #7 of 24 (permalink) Old 10-09-2014, 10:55 AM Thread Starter
Registered User
 
JohnBFisher's Avatar
 
Join Date: Sep 2014
Country: United States
First Name: John
Posts: 22
 
Default

Quote:
Originally Posted by boogalee View Post
IMHO I would not use a silicone spray. It has the ability to mess up a finish. ...
Thanks for the heads up! No point in learning a lesson the hard way!!

Quote:
Originally Posted by boogalee View Post
... Dewalt 625 is rated @ 15 amps and a shop vac can be rated @ as much as 12 amps. I think a small appliance cord to be to small (wire gauge wise). ...
Sorry. I used "small appliance" in the post, when I had searched for and used "power tool" when searching for the cord. I did take the load into account and used a heavier gauge (12 gauge, 3 conductor) cord. I used a search on amazon to find such a cable: "power tool replacement cord 12/3".

But thanks for the caution. I will keep an eye on it.
JohnBFisher is offline  
post #8 of 24 (permalink) Old 10-09-2014, 11:00 AM Thread Starter
Registered User
 
JohnBFisher's Avatar
 
Join Date: Sep 2014
Country: United States
First Name: John
Posts: 22
 
Default

Quote:
Originally Posted by timbertailor View Post
... There is a photo of a folding router table design ... It was a pretty slick design. ...
If you find the pointer, before I find it, I would be interested.

Quote:
Originally Posted by timbertailor View Post
... And ditto on the silicone. No bueno for wood surfaces\finishes. ...
Thanks also for this caution!! I will avoid, since I don't need to learn a lesson by repeating mistakes others have already made. I try to not just learn from my own mistakes, but also learn for the experiences of others.
JohnBFisher is offline  
post #9 of 24 (permalink) Old 10-09-2014, 01:19 PM
Registered User
 
Join Date: Aug 2014
Country: United States
First Name: Allen
Posts: 365
 
Default

Looks very nice so far. Please keep the pictures coming.
Allen
firstmuller is offline  
post #10 of 24 (permalink) Old 10-09-2014, 02:18 PM
Registered User
 
RainMan 2.0's Avatar
 
Join Date: May 2014
Country: Canada
First Name: Rick
Posts: 16,072
 
Default

Brad I tried to find that folding router table last week and couldn't for the life of me ? It's not a very old post either

I donít always insulate , but when I do .
Ok ,I never insulate
RainMan 2.0 is online now  
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Router Forums forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in











Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
New Router my way reible General Routing 21 12-08-2018 12:06 PM
Ridgid R2930 (fixed and plunge base routee) xplorx4 Tool Reviews 15 09-23-2014 09:15 AM
New Router Table flemingj1122 Table-mounted Routing 13 05-19-2012 04:02 PM
Rigid Model R2900 Router Combo and Ryobi Model A25RT02 Router table bigdave720 Table-mounted Routing 12 04-05-2012 08:27 PM
New router, need table, building dovetail cabinets santana157 General Routing 7 02-03-2009 12:34 AM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome