RainMans router table build thread - Router Forums
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post #1 of 189 (permalink) Old 06-15-2015, 09:07 PM Thread Starter
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Default RainMans router table build

This is a router table to replace my table saws factory extention .

Guys and Gals I did my first cut . A full sheet of 3/4" MDF is to much for this old man to handle so I had them cut it in half with there panel saw . This concerned me so I had him mark his cut so I could push the factory cut threw my table saw in order to hopefully end up with the top being square .
After calibrating my fence with a dial gauge for zero runout , I end up with a discrepancy .
If you look at the pics you can see the new piece of MDF laying on top of the factory extention . It is lined up at the front of the table saw .


The bad news is if you look at the pic below at the top where I wrote good , the factory extensions melamine underneith is exposed about a 1/32" , meaning my piece came out anything but square (verified with a square also ) . Now I can afford to take more off and I'm tempted to try my track saw and correct this , or just let that 1/32" be ? Both ends have the same outcome
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Last edited by RainMan 2.0; 06-15-2015 at 09:40 PM.
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post #2 of 189 (permalink) Old 06-15-2015, 10:07 PM
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If you can find one edge that has good 90* corners at both ends, put that edge against your fence and rip a new edge opposite the reference edge. In a perfect world that will give you 4 good 90* corners.
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post #3 of 189 (permalink) Old 06-15-2015, 10:11 PM
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Yeah , but it actually wasn't YOUR first cut now was it?

Anyway, not sure I understand the dilemma but I'll give it a try. Is the piece marked "GOOD" actually square and the piece underneath the rip made by the panel saw?

If the piece marked GOOD is square, then how about using a flush trim bit to match the two pieces and remove the extra "unsquare" portion?

But... if the piece marked good doesn't have a square corner, then it's time to square it up with your track saw, then go to the previous step
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post #4 of 189 (permalink) Old 06-15-2015, 10:33 PM
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Did you measure diagonally across both ways to see if there is any difference? Maybe the melamine is not square.

That's my story and I'm stickin' to it!
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post #5 of 189 (permalink) Old 06-15-2015, 10:46 PM Thread Starter
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Mike I crossed referenced with the square after I cut so I know I scewed up . I was certain I was working off a perfectly square end when I pushed it threw the table saw, but the apparently not ?

Anyways , I fired up my new Festool track saw and the problem is averted . I created a square end then pushed it threw the saw again , and it's square now . I did have a bit of extra length so a 1/32 wasn't an issue .
Not liking the track saw to much as its for lefties IMO

Ok this plate you see laying on top goes underneath at approx that same location . It is from Incra and has predrilled screw holes for the Allen head screws to adjust the plate plus holes for there dust collector . As you can see there won't be a lot of real estate for the torsion box



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Ok ,I never insulate

Last edited by RainMan 2.0; 06-15-2015 at 11:03 PM.
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post #6 of 189 (permalink) Old 06-15-2015, 10:59 PM Thread Starter
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Originally Posted by vchiarelli View Post
Yeah , but it actually wasn't YOUR first cut now was it?

Anyway, not sure I understand the dilemma but I'll give it a try. Is the piece marked "GOOD" actually square and the piece underneath the rip made by the panel saw?

If the piece marked GOOD is square, then how about using a flush trim bit to match the two pieces and remove the extra "unsquare" portion?

But... if the piece marked good doesn't have a square corner, then it's time to square it up with your track saw, then go to the previous step
Yes you called it Vince . I swore it as the good factory corner ,but something went south as it wasn't . The track saw fixed it . I have to I wonder how the heck I got by without a track saw after trying one . Pretty neat unit but the blades on the opposite side as a skill saw which I find awkward
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post #7 of 189 (permalink) Old 06-15-2015, 11:15 PM Thread Starter
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I guess tommorow I'll get some 3/4" plywood . I was going to build the sides from MDF but seeing as there's not a lot of room for as much of a torsion box as I'd like , I'll make the perimeter sides from plywood to as I it should prevent warping more I suspect

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Ok ,I never insulate
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post #8 of 189 (permalink) Old 06-16-2015, 12:19 AM
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MDF is a poor choice for a torsion box Rick but there is nothing wrong with using plywood. The I-joists that are commonly used in place of solid wood floor joists are 9+" of 7/16 OSB with wooden caps on the edges to help prevent torsion. Plywood is stronger yet, just more expensive.

Someone I consider a master woodworker once told me that a master woodworker is not someone who never makes mistakes. He is someone who is able to cover them up so that no one can tell.
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post #9 of 189 (permalink) Old 06-16-2015, 12:37 AM
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Rick you've started. Should have it ready by Friday seeing as you are off this week.
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post #10 of 189 (permalink) Old 06-16-2015, 01:08 AM Thread Starter
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Rick you've started. Should have it ready by Friday seeing as you are off this week.
Geez I'm hoping it's done tommorow , but if the glue takes long to set it may be another day


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MDF is a poor choice for a torsion box Rick but there is nothing wrong with using plywood. The I-joists that are commonly used in place of solid wood floor joists are 9+" of 7/16 OSB with wooden caps on the edges to help prevent torsion. Plywood is stronger yet, just more expensive.
Yes the only MDF will be the top . 3/4 ply for the sides and torsion box .
I am going to glue laminate on the sides as well but put a piece of wood on the exposed end as I don't want sharp edges.
Speaking of laminate , it might be a little precarious doing the sides with a full size router . Maybe I'm going to have to break down and buy a laminate router . Any suggestions on the best choice ?

Ok just did some research and the Bosch Colt got first prize . Of course there won't be one in this one horse town

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

Last edited by RainMan 2.0; 06-16-2015 at 01:36 AM.
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