I thought a couple of exploded views might be useful.
Oh, and I closed up the ends and added center support in the spacer boxes.
GCG
Oh, and I closed up the ends and added center support in the spacer boxes.
GCG
Router Insert for a Ridgid R4510 Table Saw
I've had my new saw a week now and I've decided to use the space that opens up when the table is extended for a router table insert. I've checked clearances and I think some 3/4" aluminium angle, carefully cut to fit the inner groove of the rails should support the insert and leave enough room for a standard router plate from Grizzly. (Thanks Jigs). Only problem is the plates are on back-order and won't come in till June 1.
In the mean time I'll work on getting the fence mod going. I have a preliminary design I've thrown together on Google Sketchup. The large silver extrusion is the table saw fence. The white one is Incra's T-track Plus (probably will use two to get measurement on both ends). The brown is 1/2" and 3/4" MDF. If any one sees any glaring mistakes please let me know.
GCG
In the mean time I'll work on getting the fence mod going. I have a preliminary design I've thrown together on Google Sketchup. The large silver extrusion is the table saw fence. The white one is Incra's T-track Plus (probably will use two to get measurement on both ends). The brown is 1/2" and 3/4" MDF. If any one sees any glaring mistakes please let me know.
GCG
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One more of the whole concept.
GCG
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Clyde,
I took one of your suggestions and put the TTrack Plus on the top and replaced it with a standard track. I made the support boxes shallower and added support on the top across the top of the saw fence. Then I dropped in some fasteners for clarity. I've shifted the positions of the slide-able sections to show the fasteners that would otherwise be hidden.
GCG
Addendum: The 1/4-20 screws that the aux fence sections ride on will be in threaded inserts (I have some from a previous project). That's why I'm not going to use track there. Should have been clearer on that.
I took one of your suggestions and put the TTrack Plus on the top and replaced it with a standard track. I made the support boxes shallower and added support on the top across the top of the saw fence. Then I dropped in some fasteners for clarity. I've shifted the positions of the slide-able sections to show the fasteners that would otherwise be hidden.
GCG
Addendum: The 1/4-20 screws that the aux fence sections ride on will be in threaded inserts (I have some from a previous project). That's why I'm not going to use track there. Should have been clearer on that.
Attachments
Added the Saw table for some context.
First pic: full layout with the fence at the right most position allowable.
Second pic: Fence, TTrack, and Plate removed to show the cutouts in the top (3/4 Melamine).
Third pic: Top removed to show the 1/2 MDF base inside the frame sections.
GCG
First pic: full layout with the fence at the right most position allowable.
Second pic: Fence, TTrack, and Plate removed to show the cutouts in the top (3/4 Melamine).
Third pic: Top removed to show the 1/2 MDF base inside the frame sections.
GCG
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Over 160 views and no one is warning me off so I guess I can move forward.
Two dimension drawings
1. Aluminum angle detail
2. Top and base detail
GCG
Two dimension drawings
1. Aluminum angle detail
2. Top and base detail
GCG
Attachments
Had my head locked into the saw operating position. Need to open up with my thinking.
Lucky for me they're both reversible. The saw fence has a symmetrical t-slot layout so the the router fence addition (also symmetrical) can go on either side. The insert is basically a 10.25x21 inch rectangular table leaf that rides on the table rail grooves so it can go either way too.
New pic. ... Better?
The only inconvenience will be that the lock for the fence is on the near side and if I'm feeding safely from the far side, I'll have to walk around to make adjustments. No biggie, just an observation.
GCG
Lucky for me they're both reversible. The saw fence has a symmetrical t-slot layout so the the router fence addition (also symmetrical) can go on either side. The insert is basically a 10.25x21 inch rectangular table leaf that rides on the table rail grooves so it can go either way too.
New pic. ... Better?
The only inconvenience will be that the lock for the fence is on the near side and if I'm feeding safely from the far side, I'll have to walk around to make adjustments. No biggie, just an observation.
GCG
Attachments
I have the ridgid ts3650 with the same fence and this is what I did for a fence for my router insert in my table saw.
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I made mine taller due to the fact I was doing alot of taller pieces and also for the ability to put a feather board from the top.
I had been using this fence for about 3 years but it had alot of short comings that I think I took care of in the above design.
![Wood Machine Machine tool Tool Tool accessory]()
![Wood Tool Table Machine tool Plywood]()
I made mine taller due to the fact I was doing alot of taller pieces and also for the ability to put a feather board from the top.
I had been using this fence for about 3 years but it had alot of short comings that I think I took care of in the above design.
Little by Little ...
Got the angle cut and fit. The long 3/4 x 3/4 run lengthwise along the sides of the table sections and act as ledgers and the shorter 3/4 x 1/2 pieces are cross members to support the insert. The cross members will be attache to the insert and I'll drill and tap the ledgers at the cross points to use jacking screws to level the insert to the table. The two middle cross members will be cut to fit the plate opening once I've got the plate in.
GCG
Got the angle cut and fit. The long 3/4 x 3/4 run lengthwise along the sides of the table sections and act as ledgers and the shorter 3/4 x 1/2 pieces are cross members to support the insert. The cross members will be attache to the insert and I'll drill and tap the ledgers at the cross points to use jacking screws to level the insert to the table. The two middle cross members will be cut to fit the plate opening once I've got the plate in.
GCG
Attachments
2
Gettin' there
After some distractions I finally got back to the insert project. I've finished the insert and as far as the final product is concerned I'm very happy. Here's a shot from my phone.
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[/url] Saw table Router insert complete by pat w1, on Flickr[/IMG]
and underneath with the Bosch 1617,
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[/url] Saw table Router insert complete below2 by pat w1, on Flickr[/IMG]
You can see the four leveling screws at the corners. I need to cut them down if for nothing else aesthetics. I may or may not try to retrofit the safety switch from the original table. I could just set it up as a utility table to the side and plug the router and shop-vac to it as is. It'll still be handy enough for a safety.
I had some play in the guides I used to route the recess for the router plate which resulted in a plate that shifted between 1/16 and 1/32 in both axes. To correct this I made a paste with sander dust and glue with a consistency about like thick peanut butter. I laid in some along the back (away from the t-track) and left side. I laid down some wax paper and then set the plate in. After it set up overnight I cleared away the excess with a chisel. Now there is no noticeable play at all.
I've delayed the fence. I've been working on getting some reclaimed red oak and I delivered a load to a local mill yesterday. It was 11 distressed 6x8 10' ties. The guy at the mill will cut it down for me for half the lumber, fair enough. As soon as I get it back (he said probably Tuesday) I'll start work on the fence.
GCG
After some distractions I finally got back to the insert project. I've finished the insert and as far as the final product is concerned I'm very happy. Here's a shot from my phone.
and underneath with the Bosch 1617,
You can see the four leveling screws at the corners. I need to cut them down if for nothing else aesthetics. I may or may not try to retrofit the safety switch from the original table. I could just set it up as a utility table to the side and plug the router and shop-vac to it as is. It'll still be handy enough for a safety.
I had some play in the guides I used to route the recess for the router plate which resulted in a plate that shifted between 1/16 and 1/32 in both axes. To correct this I made a paste with sander dust and glue with a consistency about like thick peanut butter. I laid in some along the back (away from the t-track) and left side. I laid down some wax paper and then set the plate in. After it set up overnight I cleared away the excess with a chisel. Now there is no noticeable play at all.
I've delayed the fence. I've been working on getting some reclaimed red oak and I delivered a load to a local mill yesterday. It was 11 distressed 6x8 10' ties. The guy at the mill will cut it down for me for half the lumber, fair enough. As soon as I get it back (he said probably Tuesday) I'll start work on the fence.
GCG
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