Table Saw Router Extension Delta 36-725

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Project by EricLew posted 11-29-2014 07:03 AM 41216 views 29 times favorited 34 comments Add to Favorites Watch

Updated 12/6/2014 with Fence and Dust Collection

Updated 3/1/2015 with T-track and Safety Power Switch

Here is my first project since I recently got back into woodworking. I know this is a basic project that countless others have done, but in all my searching for ideas, the only one I found that was made on this Delta 36-725 table saw was by Tinman, and they are very different, so I thought I would post it.

The funny thing is, even on a pretty simple project like this, it’s incredible how many decisions there are to make. What side to mount it on, how big to make it, what materials to use, what insert plate to use, if any, and on and on.

Because of the layout of my garage woodshop, I had to install on the left, which was my first choice anyway. This saw has a two piece fence rail system, the left side rails only extend 10 inches past the cast iron top, where the steel wing mounts. I thought about replacing the left rails with longer ones and building a bigger router wing, but decided against that. I ended up with a wing that is 27 inches by 16 inches. I spent a lot of time deciding on the table material and thickness, I felt ¾ was too thin but was concerned about the weight of going 1½ because the rails didn’t run to the end of the wing.

I ended up with a hybrid design, if you look at the pictures from below, the top is ¾ inch MDF, which I laminated with white Formica, and then I installed 2 panels of ¾ oak plywood. This gave me a stronger support area for the router, and saved some weight. I also made sure I had easy access to the location of the mounting hardware. It’s wrapped in 1X3 select pine and the top is chamfered on 3 sides. Everything is glued & screwed/nailed. It’s hard to see in the picture, but I had to cut two ¼ inch notches in the pine board in back that mounts to the cast iron top so it would fit on the bump out on the left side of the saw body.

As you can see, I decided on the Kreg router plate and levelers. Which like many other plates was pre-drilled for my new Bosch 1617EVSPK (what a great router). The plate leveler installation instructions were detailed and easy to follow. The one thing I didn’t realize, until I was finished and doing the final mounting, was that the levelers hit the bump out I mentioned earlier. Luckily, it was easy to route out the material in the plywood panels, and inset the back levelers.

I also got an unexpected bonus, the saw has those 2 brackets on the side, for storing the fence when you’re not using it, which I would never do. They are perfect for winding the router cord. Because I have a magical shop where tools and accessories seem to vanish :-) I put a few nails in the underside of the frame to hang the wrenches, and insert rings.

This was the first project I have done in about 12 years, I’m very happy with the way it turned out. I now need to make a fence with dust collection and maybe install a T track. I will post an update when that’s completed. Thanks for reading.

Regards, Eric

-- I love the smell of coffee in the morning, and sawdust in the afternoon

34 comments so far

View Farrout's profile


188 posts in 3609 days

#1 posted 11-29-2014 12:36 PM

Nice job. I wish now that I had put mine on the left.

-- If we learn from our mistakes, I should be a genius!

View Ken90712's profile


17701 posts in 3643 days

#2 posted 11-29-2014 06:39 PM

Great work, you’ll wonder how you lived w/o this once using it. Very clean and goodlooking project.

One thing to consider if you ever change routers, although Bosh is great router. Triton (and I think a cpl others now) plunge router does not require a lift system. You remove the plunge spring and drill a hole in the router table and your able to do adjustment and bit changes w/o bending over or lifting the router out. Just some info to think about.

-- Ken, "Everyday above ground is a good day!"

View danoaz's profile


223 posts in 2624 days

#3 posted 11-30-2014 04:37 PM

I have been considering this for a long time because of my limited space. I am curious why you picked that side. I see that in several posts. I have a Ridged 4512 TS that is begging for a router table on the right side. Nice job and it seems it will certainly work for you.

-- "Simplicity and repose are the qualities that measure the true value of any work of art." Frank LLoyd Wright

View EricLew's profile


240 posts in 1820 days

#4 posted 11-30-2014 05:24 PM

Thanks guys for your kind words.

The reasons I chose the left side are:

The layout of my workspace, there is very little room past the right side of the saw.

I like that the feed direction for the saw and router are the same, I plan on using some type of out feed support in the future. Plus, it’s also related to the available space around the saw.

The fence rails on the right side side are much longer, and different lengths, and the spreader bar is there as well, since I wasn’t going to build a wing that large, the rails would be in my way moving around the router wing.

-- I love the smell of coffee in the morning, and sawdust in the afternoon

View James Frederick's profile

James Frederick

191 posts in 4175 days

#5 posted 12-02-2014 10:11 PM

That looks great have you thought about dust collection, I only ask because building a project like this one is on my list…... after the 4 craftsman bookcases, table for my mother in law, and another table for my neighbor…

-- Change begins somewhere may as well be with me.

View EricLew's profile


240 posts in 1820 days

#6 posted 12-03-2014 02:48 AM

I am in the process of building a fence with dust collection, and still deciding on how to handle the under table solution. I will post an update when i finish the fence

-- I love the smell of coffee in the morning, and sawdust in the afternoon

View EricLew's profile


240 posts in 1820 days

#7 posted 12-07-2014 07:26 AM

I completed the fence today. I looked at what fellow woodworkers had done, and ended up combining the features I liked best from a couple of them, and changing the dimensions to fit my needs.

It’s a standard design, that “box” at the end of the fence fits over the end of the table saw fence, and the unit slides in place. It also ensures that the center and opening in the router fence is perfectly centered at the router collet. The nice thing is I never have to worry about the fence sliding as I’m feeding stock down the table. I added those two small fence clamps just to hold the unit against the Delta fence, but they don’t need to be very tight, which is good, because I don’t want them to cause any damage. The reason I didn’t make the box the entire length is I’m always trying to reduce size and weight.

It’s all glued and nailed together with brads

So far its all the same left over plywood I used for the panels under the router table.

Then I laminated some MDF and added the front panels, the bottom pieces slide side to side and are attached with T-bolts through the back. The top panels are screwed in place, and I routed a slot to attach feather boards. The top panel would have been one piece if I had a longer piece of scrap MDF.

Here is the finished back view, with the dust collection and hardware.

The table and fence were a lot of fun to build, and will get a lot of use.

-- I love the smell of coffee in the morning, and sawdust in the afternoon

View EricLew's profile


240 posts in 1820 days

#8 posted 12-26-2014 10:45 PM

Today I added the Dust Router from Keen. You can find a few reviews of this product on this site. I was going to add a review of it, but it would have been exactly the same as the one posted by ardbeg. It is a great product. I ran 12 feet of scrap through cutting a rabbet in the edge, and I would say 95% of the dust got vacuumed up. Because I don’t have a stand alone router table, one of the included hoses wasn’t long enough for my configuration. I purchased a Shop-Vac 1-1/4 in accessory hose kit which includes an assortment of connectors and 8 feet of hose, so I was able to combine parts and get the setup I needed.

Here is the under table “Dust Cup” and Hose view

The Hose setup

This is all the sawdust left on the floor after running the 12 feet of material through.

-- I love the smell of coffee in the morning, and sawdust in the afternoon

View kirbi69's profile


83 posts in 2038 days

#9 posted 12-27-2014 02:20 AM

Super nice!

I just got a craftsman 2 hp variable speed router for christmas, and just built a router table extion on the right side of my saw. My design is way simpler than yours but it should suit my needs for now. Great job

View kirbi69's profile


83 posts in 2038 days

#10 posted 12-28-2014 12:36 AM

View EricLew's profile


240 posts in 1820 days

#11 posted 12-28-2014 07:00 AM

Good work Kirbi, that’s a nice big work surface. Did you drill additional holes in the fence rails to mount it? Did you remove the spreader bar or work around it? Besides being curious, I have been thinking of replacing the right steel wing on mine with a bigger work surface

-- I love the smell of coffee in the morning, and sawdust in the afternoon

View kirbi69's profile


83 posts in 2038 days

#12 posted 12-29-2014 01:24 AM

Its only attacked to the edge of the stamped steel extension wing. Nothing on the fence rails.

And the table actually just rests on top of the spreader bar, with a shim for the height.

I figure this way it is easily replaceable.

View EricLew's profile


240 posts in 1820 days

#13 posted 03-02-2015 05:24 AM

Today I finally added a T-Track and Safety Power Switch.

Both of these are Rockler items. The safety Switch is great, having to blindly grope under the table for the power switch on the router is always nerve racking. Although its probably impossible to get hurt on the router like that, its still weird, and more of a concern that it takes so long to shut off the router. Also when doing stop grooves and dados there’s a chance the work piece could move unintentionally when I’m bending down and shutting off the switch.

The way I installed the T-track is probably a little unusual. It doesn’t go edge to edge, I used a 24 in track, because there were brad nails in the frame that would have been in the way (through poor planning) so when I routed the dado for the track, I made it a half inch long on both ends, that’s how I insert the bolts for the Jessem feather boards, which are great featherboards.

I really love this extension wing, I use it all the time

-- I love the smell of coffee in the morning, and sawdust in the afternoon

View grantd's profile


105 posts in 1937 days

#14 posted 08-18-2015 02:52 AM

Excellent build. I have the same saw and router and will be adding a router table to one side in the semi near future. Now that you have had it for awhile do you feel like the table is big enough? Would you put it on that side again? I have the right side of my saw against the wall so having the table on the left would be more convenient but I’m nervous about the size.

View EricLew's profile


240 posts in 1820 days

#15 posted 08-18-2015 03:45 AM

Thank you. The table size works fine for me. I love having it on the left side because I have a big out feed table I setup when needed and, like I said above, having the feed direction the same as the saw is very handy.

If you’re concerned it wont be large enough, I will tell you it is really solid with the 6 mounting bolts. I think you could extend it out another 4 inches or so without any problem because the router is mounted back by the bolt area. If you build it that big and don’t feel it’s supported well enough you could just move it to the right, or cut it down.

Whatever you decide, enjoy. These are fun to build, and we look forward to seeing your results.

Best wishes

-- I love the smell of coffee in the morning, and sawdust in the afternoon

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