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Table Saw Extension / Router Table

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Blog series by Dave Rutan updated 09-23-2013 07:38 PM 5 parts 13818 reads 2 comments total

Part 1: I Gots da Wood

09-10-2013 09:20 PM by Dave Rutan | 2 comments »

Because I am often frustrated by the limitations of my small table saw, I decided to put this project on the front burner. Today I drove up to a friend’s house to rescue him from being buried under too much wood. I came away with some 1/2 inch plywood less than 2 feet square and a few other goodies for future use. Then I headed down to my big box store and bought some hardware and a sheet of 1/2 inch plywood. I had it cut in quarters so that it would fit in my car. (Last time I asked...

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Part 2: The Cuts are Made. Time to Start Gluing.

09-13-2013 03:02 PM by Dave Rutan | 0 comments »

Having recalculated my cuts for this cabinet, I have enough to the entire cabinet, plus the 3 drawers. It will measure about 16×16 inches by 34 inches high. The router table top will be 20×16 inches. I’ll be making a router fence to clamp onto my table saw rip fence. I scored a few pieces of wood that I can use to make the combined unit mobile. I wish I had made this one first since a lot of the cuts were made with a handheld circular saw. I’m going to need to buy ...

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Part 3: Working on the top

09-16-2013 05:25 PM by Dave Rutan | 0 comments »

I’m going to finish the top and install it before installing the drawers. It should be easier that way to get my hands inside, plus I always build the drawers last just in case my ideal measurements were not met. This wooden piece matches the profile of the edge on the table saw, allowing me to use the rip fence further away from the blade and also use the rip fence to hold my router fence. The piece will be attached on the edge of the router table top. Here is a better view of t...

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Part 4: Starting to take shape

09-18-2013 11:36 PM by Dave Rutan | 0 comments »

Today’s efforts went into building the router table insert onto which the router will be mounted. I laminated a piece of Luan to the 1/2 inch plywood to make it look nice. The underside of the plywood has been routed out to a thickness of about 1/4 inch. I hope to create different throat inserts for when I have smaller work pieces. I also installed 3 lengths of 3/8 inch threaded rod with which the cabinet will be fastened to the table saw. That way I can remove it if I should wa...

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Part 5: Top is Done

09-23-2013 07:38 PM by Dave Rutan | 0 comments »

[See the finished project here] Well, I got the top of the router table done. The next step is to make the 3 drawers that go in the cabinet. Shown in the photo is my set up for milling the rabbets and dados in the drawer pieces. I temporarily put the sacrificial fence from my table saw on the table saw fence to use with the router. The last part of this project before painting will be to make a proper router fence. It will still attach to the table saw rip fence, but will have a few...

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