Bass Bully's Router Table #1: Research

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Blog entry by BassBully posted 03-13-2007 11:58 PM 3311 reads 1 time favorited 9 comments Add to Favorites Watch
no previous part Part 1 of Bass Bully's Router Table series Part 2: Making the Substrate »

This project series is going to journal the development of my new router table. In this post I will begin the series by describing the components that I purchased for this project and why, and in later installments, I will describe the construction process as I go. It probably isn’t necessary to explain the benefits of having a router table; however, with all of the various options available in the marketplace, it might be helpful to understand why I chose the components that I did.

I’ve built router tables before; however, they were quickly cobbed together in order to meet a temporary need. Now I have the ability to have a permanent yet mobile fixture in my shop that I desire to be highly accurate. I would have preferred to purchase a complete pre-manufactured system to save myself time; however, I tend to be frugal and decided to meet cheap and efficient somewhere in between. I also discovered, through my research, that complete systems aren’t always complete and no particular router table system met all of my desires. Thus, I decided to “piece-mail” the system together.


The Bench Dog tables were my favorite tables by far. They are not made of metal, they have nice thick tops, and they come pre-fitted for their router plate insert. I also liked their fence and custom t-track. Many other “complete” systems on the market are built with metal legs requiring me to build a cabinet within/around the system. I didn’t feel it necessary to purchase a $400 system that required me to spend another $120 for material to achieve my desired result.

Although I liked the Bench Dog tables, I didn’t like the price. Their top Baltic birch cabinet costs around $550 but drawers and doors cost extra. Plus, their phenolic router plates do not provide different sized rings for different sized bits. This means that I would have to purchase about two additional plates so that I can fit my raised panel bit or other sized bits into it. These are even more reasons why I decided to build my own cabinet.

Router Fences

I thought about building a custom fence, but the fences that exist today have so many features and are so accurate that I decided it would be a waste of time to replicate them. I scoured over many options, but the router fences that really caught my eye were JessEm’s, Bench Dog’s, Rockler’s, Woodpecker’s and Rousseau’s.

Rousseau has a nice fence but only being able to see it on the web, it appeared that some of the adjustment knobs were in tight places. They were priced competitively though. I liked the Rockler and Bench Dog fences but compared to JessEm’s and Woodpecker’s fences, they were pretty basic.

I almost decided to go with the JessEm fence because I really liked its measuring track that sits to the to the left and right side of the table where the fence tightens into. However, I changed my mind when I found out that the front movable fence faces are tightened in the front rather than the back. It would become annoying getting my allen wrench every time I wanted to adjust the faces.

The Woodpecker router fence is just what I need. It uses aluminum angle “iron” that the face plates attach to which will keep it sturdy. Also, the aluminum angle has tapped holes drilled for leveling screws to keep the fence at a 90 degree angle. Like the others, the fence plates have t-tracks in them and most importantly, a dust collector attachment on the back.

The only complaint that I have about the fence would be the fact that Woodpecker company has decided to allow Woodcraft to sell their fences and in the license agreement, Woodpecker is no longer allowed to sell their fence online at their site. This was frustrating because I had to purchase my Woodpecker fence and router plate from separate companies.

Router Plate Inserts

I decided to go with an aluminum plate for this project. My Bosch 1619EVS is heavy and there were some concerns on internet posts that phenolic plates may warp a little with varying temperatures. These claims may be unfounded but why take the chance. Besides, this is going to be my special router table project.

To defend phenolic plates, I already have one which is manufactured by Rousseau. The removable rings make it nice for different sized plates. Likewise, the phenolic material is easy to drill through for different router bases. The only reason I didn’t go with this plate for my new table is because the plastic rings are not precisely flush with the phenolic plate. As stated before I want a large degree of accuracy for this table and aluminum plates seem a better choice for this reason.

I chose Woodpecker’s aluminum Plungelift router table insert over all other aluminum products for the main reason that the ring inserts are the easiest to remove. Rockler’s and other competitors’ aluminum plates would require me to remove screws to change the ring inserts. Woodpecker has innovatively allowed users to remove rings with a tool by twisting the ring and pulling it out.

Construction Material

For the router table top and cabinet I am using Baltic Birch plywood. It is a clean, sturdy, and professional looking material when finished. However, it is expensive but I have never used it before and it will last a long time. I chose this over 5-play and MDF because my shop’s climate changes frequently and admittedly I’m splurging a little.

I also decided to apply a Formica veneer to the top and bottom of the router table top. This will insulate the substrate from humidity and also provide a slick surface to move wood across while routing.


I purchased a combo t-track/miter t-track from MLCSWoodworking. Rockler has one but it is double the price and MLCSWoodworking provided free shipping.

I also purchased two 3” locking casters and two 3” standard casters for mobility.

Finally (or just the beginning)

Hopefully this weekend I can begin cutting the Baltic Birch for the top and get the Formica attached to it. My next post will describe the top making process.

-- There are three types of people in the world, those who can count and those who can't!

9 comments so far

View Don's profile


2603 posts in 4595 days

#1 posted 03-14-2007 12:11 AM

Great article, Double-B. Any possibility of pictures to accompany your journey?

-- CanuckDon "I just love small wooden boxes!"

View BassBully's profile


261 posts in 4515 days

#2 posted 03-14-2007 12:47 AM

Yes, I will have pictures. I’m looking forward to posting them.

-- There are three types of people in the world, those who can count and those who can't!

View Karson's profile


35193 posts in 4819 days

#3 posted 03-14-2007 02:08 AM

I hope your casters are all swivel. I curse every tool that has non swivel casters on them. I get them convertout as fast as I can.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected]

View Don's profile


2603 posts in 4595 days

#4 posted 03-14-2007 02:30 AM

Karson, great suggestion. I’ll fix mine today as I have a router table without casters – and I have casters, so no excuse here.

-- CanuckDon "I just love small wooden boxes!"

View WayneC's profile


14358 posts in 4516 days

#5 posted 03-14-2007 04:20 AM

Looking forward to see how it comes out. I went the pre-fab route. Given my current work schedule, time is precious.

-- We must guard our enthusiasm as we would our life - James Krenov

View MsDebbieP's profile


18619 posts in 4579 days

#6 posted 03-14-2007 01:36 PM

This is wonderful. I love all the tips on things to think about when deciding on what works best for you.
Very insightful for someone like myself.
I too am looking forward to the upcoming blogs.

Thank you for sharing your journey with us—and you deserve to splurge!! :)

-- ~ Debbie, Canada (, Young Living Wellness )

View Christian's profile


14 posts in 4516 days

#7 posted 03-23-2007 07:56 AM

Hey neighbor, Good post.

View Jeff's profile


1010 posts in 4512 days

#8 posted 03-23-2007 08:46 AM

Good info, BB. I’m going to take this research into consideration for a table. I have a Rockler setup but it’s just a stop gap I think.

I can’t remember if it is Bench Dog or Woodpecker that has a table system that replaces the left wing on you table saw. Did you come across such a thing in your research?

-- Jeff, St. Paul, MN

View BassBully's profile


261 posts in 4515 days

#9 posted 03-23-2007 03:22 PM


Thanks for the comment. Both the Bench Dog and the Woodpecker companies have a table system that replaces a wing on the desktop. Peach Tree Woodworking Supply also has them. Bench Dog and Peach Tree offer both metal and MDF while WoodPecker offers MDF. I don’t have a preference whether it is steel or MDF except MDF is obviously much cheaper and lighter.

-- There are three types of people in the world, those who can count and those who can't!

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