Delta Router Table extension

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Project by ilyac posted 07-26-2015 10:06 PM 22567 views 19 times favorited 3 comments Add to Favorites Watch

This is a router table extension wing for my Delta 36-725 Tables saw, which having used it for several months, I can safely say I am extremely happy with. The extension is made of 3/4” MDF with a 2.5” pine skirt around it (all from Home Depot). It’s all assembled with pocket screws and glue, because it was quick an easy.

I had a choice of putting it on either the right of left side, and I chose the right side because I wanted a little extra usable surface area in my shop, and I hate plopping down things on the cast iron. replacing the left side would have not given me any extra area, and for many thinner cuts I would not even have to drop the router because it is not until about an 18” cut that the fence would even go near the bit area.

I also put a small bit of extra support pine under the top aside from the skirt, so help reduce the chance of sag over time since the top is pretty big.

I cut the opening to the Kreg plate by building a small frame right around the actual plate, and then stuffing bondo body filler into the corners to match the 3/4” radius semi-circle. I wish I could take credit for that very clever trick, but I found it on Rockler (Link). I also used the Kreg plate levelers, though in retrospect I could have easily done without them and gotten a very nice level surface.

leveling it with the rest of the table saw was a pain, but it’s in there pretty good and do not suspect it will move much. It’s not as dead flat as I would have originally liked, but it’s damn close enough. maybe one day I’ll spend the $25 and re-do it a little cleaner.

This was a pretty simple project that ended up dragging on for a lot longer than I originally intended, mostly just due to my own lack of focus to spend a single full day cutting the pieces and putting them together. Instead I chose to split it over several 2 hours days for some inexplicable reason.

3 comments so far

View exelectrician's profile


2339 posts in 3273 days

#1 posted 07-27-2015 04:23 AM

Very nice, and super idea on the opening jig…

-- Love thy neighbour as thyself

View Grant Davis's profile

Grant Davis

836 posts in 4754 days

#2 posted 07-27-2015 10:15 AM

Nice addition

-- Grant...."GO BUCKEYES"

View Scott Landry's profile

Scott Landry

210 posts in 2316 days

#3 posted 07-27-2015 01:53 PM

I’m doing the same project and agree that it takes longer than it should. You might want to schedule a few more days to make a nice fence. I opted to leave in the cast iron wing on my saw and make the router insert very small. I like your idea with the Kreg levelers. May have to get some of those myself.

-- Every project is an opportunity to acquire new tools and any solution that requires buying a new tool is the correct one.

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