Shop set up #1: Router Table Extension Added

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Blog entry by kenstonge posted 03-22-2011 03:26 PM 4403 reads 0 times favorited 4 comments Add to Favorites Watch
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Router table project completed!

I spent a good deal of time yesterday evening adding and setting up my router table.

Here’s what I added:

Bench Dog Router Table Extension, 40-102 ($299, see reviews here and here)
Rockler Router Lift FX ($199)

Here’s where I put it:

— Delta Contractor’s saw (1990)

Here’s what I did:

1. Using a scotch brite pads, steel wool, very fine grit sandpaper and a Boeshield kit , I treated and cleaned up the surface of the saw. Although it’s barely been used (I know this because I built it with my uncle in 1991, and it’s been in my family ever since) the saw’s surface had some rust, stains, imperfections and a few pitted areas. I spent about 90 minutes working the surface until it was largely clean, smooth and the rust was gone. Rust was the biggest concern, since I was attaching two metal surfaces. I used WD40 and T9 to treat the sides and bolt holes. It worked pretty well.

2. Using 2×4s and a Husky X-Sawhorse, I balanced the extension table and lined up the bolts. This was nice because the table weighs about 50 pounds, and in most cases it suggests using a friend. No one was home, but I was able to do it myself. Once in, the bolts went smoothly, aside from one flaw…

TAKE NOTE: Make sure the tall end of the heavy duty washers points down! It wasn’t specified in the directions, but when they were up, it caused alignment problems — as well as disassembly, reassembly and requisite curse words.

3. Once that was done, it looked good. I spent a few minutes aligning it flush with the table top, which was a lot easier than I expected. This is a fairly crucial step, I feel, so I wanted to make sure it was flush as possible.

4. I dropped in the Rockler Router Lift Fx and it fit nicely. I adjusted the depth using the 10 Bench Dog leveling screws. It was a little cumbersome but soon it, too, was flush.

5. I threw together the fence, and it was all finished. I am looking forward to trying it out.

I think my next steps are to add hookups for a dust collection system and then a Delta T2 fence. I just don’t trust the tube style fences that are on there now, and I think it would help ease some of my fears of kickback.

Eventually I also want to add a downdraft table as an extension on the other side, as well as some shelving. But those are projects for another day.

4 comments so far

View dub560's profile


615 posts in 3456 days

#1 posted 03-22-2011 04:51 PM

i’m a bit jealous because my own table saw just died today while cutting some mahogany 8/4….so i’m looking at yours with envy

-- Life is enjoyable especially when you borrow from people

View Bertha's profile


13567 posts in 3236 days

#2 posted 03-22-2011 04:57 PM

Looks like you’re due for some longer rails; you’re saw is growing! I purchased this top too but have yet to install it. Nice job!

-- My dad and I built a 65 chev pick up.I killed trannys in that thing for some reason-Hog

View Hersh's profile


106 posts in 4258 days

#3 posted 03-22-2011 06:24 PM

Great Job. I’m lookiing around for ideas for a router table on my TS. I don’t know if I want to build the table or but one. I sure like the way you did this one. I just installed the Delta T2 fence on my TS and love it.


-- Hersh from Port Angeles, WA - Gotta Complete That Project!

View Roger's profile


21014 posts in 3347 days

#4 posted 03-23-2011 02:21 AM


-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed. [email protected]

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