I am about to build my first router table, with a cabinet base. The top will be about 24" by 36" (haven't yet settled on dimensions). I will be mounting a PC 895 router. I think it weighs around 13 lbs. I plan on using 3/8" polycarbonate for the insert. For the table top and the fence I am undecided about using MDF, Baltic Birch ply, or Appleply (American version of Baltic Birch ply). I will apply a plastic laminate covering on them. For BB ply 3/4" is the maximum thickness. I believe MDF and Appleply can both be had in 1" thickness. I am not sure if one thickness is adequate for the top or should I go with double thickness? Does anyone have any thoughts on preferences for these three materials and thickness? I am asking mostly about sag resistance and stability. I live in a very low humidity area and have little humidity changes over the year.
For my top... I used 2 pieces of 3/4 MDF glued together and laminated on both sides. If you are worried about sagging, you can always add some bracing on the bottom. I don't think that will be necessary since I have a heavy Triton mounted on mine and there is no sign of sagging. I liked the MDF because it is really flat from the get-go as well as weigh more than the ply. I also used the MDF for my fence for the same reason. Good luck and post some pictures of your table for us.
If you would like to see my table and fence, check it out here:
MDF is a good material. It's cheap, flat, and machines nicely. If you can get 1" MDF, go for it. You can screw some hardwood sticks to the underside to keep it flat.The problem with making a top too thick, is that it can cause issues as far as how high above the table some bits will (won't) reach! A laminated top is nice, but not particularly necessary.
I used a double layer of 3/4" MDF. Worked great. http://www.routerforums.com/68956-post20.html
Since you are using an insert plate, you can make the top as thick as you want. It will not affect bit heights.
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