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Table Saw Router Extension Table with Storage Cabinet

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Project by CaptainKlutz posted 06-15-2019 09:07 PM 1230 views 3 times favorited 17 comments Add to Favorites Watch

Going to call this portion of my table saw upgrade project done. Has been a part time project for just over one year, ever since I picked up a used Unisaw.

Extension table:
The 54” x 26-13/16” extension table is 8/4 cherry and maple edge laminated. Made the top in two halves that fit into my 15”planer, then joined them and used hand planes to flatten.

Used hardwood instead of conventional MDF and plastic laminate for one reason: cost. Sheet of MDF + laminate to cover both sides to reduce warping was going to cost $150 in materials. Paid $2 bdft for the lumber and have about $45 in the laminated top. :-)

At first wife thought the wood plank was a kitchen cart project, but when she saw the big hole in middle and slots cut in top; found out it wasn’t for inside the house. :-)

That little stunt cost me big time. Was forced to stop working in the TS parts for a month and had to make her a x-mas stocking holder.

In order to deal with wood expansion, the top is 3/16” narrower than cast iron on saw. It is attached only at cast iron side via a supporting angle bracket, front angle bracket on back of the Unifence, and via slots/screws in top of the cabinet. By fixing the top at front and one edge, all wood movement is in back and exposed end. The back rail is attached to saw, and floats in loose screw slots via a bracket on extension table underside. Would have left the back rail off, but eventually will add a folding out feed table and will need it. :)

When I first assembled the top, used same finish I use on my workbench (Tried & True Original Wood Finish). The BLO + wax surface is perfect blend of slick and sticky on work bench. On saw table there was too much friction, so I sanded it down and added couple coats of Arm-R-Seal. Wood slides across as it should now.

Router Cabinet:
The router cabinet is loosely based on the Crestwood ’’Ultimate Router Table” Plans, with a bunch of overall size changes. It’s narrower to fit inside my custom TS mobile base (which is another work in progress).
It’s a few inches shorter to fit under the table saw extension, and it’s only 23”deep. Also moved the dust port to exit the back of saw, or side of cabinet; as I will be adding another slide out cabinet behind the router cabinet some day.

Used BB plywood with curly maple edging for cabinet. The drawer fronts are walnut. Drawer boxes are 1/2 BB plywood using box joints. Drawers use 200lb rated over travel slides, which enabled access to full drawer from top.
The only cabinet construction pictures i saved are test fitting parts as I put the saw to work as soon as the cabinet was roughed out, despite it not being completed:

Like all of my cabinet/box projects, I pre-finished the inside of cabinet before assembly. Used some GF WB Enduro Var I had laying around. The cabinet is colored with a custom blended burgundy/magenta dye stain using Transtint red, black and red mahogany. This was same color I used on my now 5 yr old work bench project. The outside of cabinet has 3 coats of Arm-R-Seal as I like how it ‘pops’’ the grain figure on curly maple and varying walnut tones.
Here is close up of Finish on BB plywood side:

Used WoodPecker’s router plate that fit my several Bosch 1617 routers. Miter slot and fence T-slot are from WoodPecker’s also. Fence is PeachTree Supreme Fence Kit. Had upgraded to this fence on my contractor saw, and kept it; selling my original nasty old Rockler router fence with old saw. :-)

One of the things I liked about the Crestwood plans is the router drawer design? They can slide out 90% of way, yet stay perched in cabinet; but can remove them completely and have easy access to very long drawer full of tools:

(sorry it’s fuzzy, was last min pic grab)

While I have 4” dust port for cabinet and 2.5”dust port in fence, not perfectly happy with how the cabinet dust collection works. Have not glued the 4” side pipe permanently, and it leaks dust. Also want to add some directional plates inside the cabinet to help direct the dust from router to pipe, and might have to add/subtract vent holes in acrylic door panel once I get it all sealed up. If I do make changes, will update this post with details.

Update: Didn’t include details on the custom mobile base as it was not made from wood? But I have included a description below in post #5 to answer a request for more information.

Thanks for reading, and have a great day!

-- I'm an engineer not a woodworker, but I can randomly find useful tools and furniture inside a pile of lumber!





17 comments so far

View Jerry's profile

Jerry

3214 posts in 2070 days


#1 posted 06-15-2019 09:16 PM

Beautiful, just beautiful, and functional too! This is a major build and I think it’s amazing! 5 Stars!

-- There are good ships and there are wood ships, the ships that sail the sea, but the best ships are friendships and may they always be. http://www.geraldlhunsucker.com/

View ruger's profile

ruger

112 posts in 517 days


#2 posted 06-15-2019 09:42 PM

very nice. your whole set up is first class.

View LittleBlackDuck's profile

LittleBlackDuck

2854 posts in 1242 days


#3 posted 06-15-2019 11:58 PM

Great job… could still have a worthy place in the kitchen… if only the missus was a woodworker.

The base is interesting… metal or timber? Blog on it would be nice.

-- If your first cut is too short... Take the second cut from the longer end... LBD

View Ivan's profile

Ivan

14668 posts in 3289 days


#4 posted 06-16-2019 04:01 AM

Wow…this is museum piece…!! This belong to living room – not workshop. One of the most beautiful router table…!!

-- Ivan, Croatia, Wooddicted

View CaptainKlutz's profile

CaptainKlutz

1507 posts in 1916 days


#5 posted 06-16-2019 09:23 AM

Thanks everyone!


The base is interesting… metal or timber? Blog on it would be nice.
- LittleBlackDuck

Sorry, not a fan of blogs, not sure why?
The mobile base is unfinished project, but here’s description of the current configuration:

Base is 2” sq 1/8” wall tubing with mitered corners, welded together. Used 1×2 tube for cross beams to define saw and router cabinet slots. There are triangle gussets welded in bottom corners for tools to sit on.
Has 4 small arms, one in each corner for 1/2” threaded swivel leveling feet if needed.

Welded mounting plates at router for bench casters, and TS side has 1×4hx22w tube with single point center mount using a bronze bushing. Plate uses 2 more bench casters.
Here is picture of version #1, where I attempted to use 3/16” plate steel for caster pivot plate. It was not stiff enough, and was replaced with rectangular tube.

With the 3 point mounting, allows the casters to roll around without twisting the mobile base (or tool tops), when floor is not level.
The design works, but the bench casters have a major problem.
The bench casters are not prevented from swiveling to low, and will fold under the caster mount/base if attempt to roll wheel across large gap inline with caster mount.
Drives me nuts. Can read/see more about my work surface challenges in mobile base review I posted? https://www.lumberjocks.com/reviews/11995

Been thrashing around different ideas on better caster arrangement. Have designs sketched out for some enlarged 4” caster versions of commercial bench caster, but my prototype had issues that required machined parts to fix, and become too expensive. Considered using pneumatic cylinders or electric screws to raise/lower casters, but cost estimate was double cost of 4” bench caster. All being too expensive for bloody mobile base.
Current plan is to replace the bench casters with simple 6” industrial casters with new welded mounting brackets similar to found on commercial mobile bases. Considering use of couple floor locks to deal with uneven floor in a temporary location, and/or extending the screws on existing leveling feet for semi-permanent location with taller casters? No idea when new caster brackets will get done as it’s project #3 on metal working/welding list ATM? LOL

Thanks again for interest.

-- I'm an engineer not a woodworker, but I can randomly find useful tools and furniture inside a pile of lumber!

View LittleBlackDuck's profile

LittleBlackDuck

2854 posts in 1242 days


#6 posted 06-16-2019 10:50 AM


.... but here s description of the current configuration…..
- CaptainKlutz

Thanks C’K’. My shop floor is like the moon surface and I am continually swapping out my smaller wheels for larger ones… I’m forever looking for bases, bought or shop-made, that do not raise the worktop by 150mm of so yet accommodate large wheels.

-- If your first cut is too short... Take the second cut from the longer end... LBD

View Peteybadboy's profile

Peteybadboy

802 posts in 2371 days


#7 posted 06-16-2019 10:59 AM

You have done an over the top job! Congratulations. I was very interested in the mobile base. Then I saw the post.
thanks for that. I look forward to your next version. I have the same saw and put a cabinet in as well. I have added those rockler casters to help with the heavy load.

Nice work

-- Petey

View knotscott's profile

knotscott

8298 posts in 3797 days


#8 posted 06-16-2019 11:36 AM

That’s a work of art!

-- Happiness is like wetting your pants...everyone can see it, but only you can feel the warmth....

View artsyfartsy's profile

artsyfartsy

1212 posts in 1580 days


#9 posted 06-16-2019 01:29 PM

Excellent Job Captain, That should serve you well. Congrats on getting the top 3 award too.

-- DWelch. Michigan, The only dumb question is the one not asked!

View Rick  Dennington's profile

Rick Dennington

6571 posts in 3616 days


#10 posted 06-16-2019 02:55 PM

Capt. Klutz,

Stellar job on building the ext. router table and set-up. It looks great, and will serve you well….Now you can do just about any project you want to, and most everything is right there handy….!! Catch you on our thread later…!!

Congrats on making the Top 3…..I figured if you ever posted it as a project, you’d have no trouble making it to the Top 3…..!! Beautifully done….!

-- " At my age, happy hour is a 2 hour nap".....!!

View Purplelady's profile

Purplelady

83 posts in 1381 days


#11 posted 06-16-2019 05:06 PM

All I can say is “WOW”!!!

-- Marsha, Northeast Ohio

View Hazem's profile

Hazem

216 posts in 1670 days


#12 posted 06-16-2019 05:30 PM

DAMN! Nicest extension/router cabinet ever.

View pottz's profile

pottz

5558 posts in 1406 days


#13 posted 06-16-2019 07:22 PM

wow ditto to all said that is a beautiful setup klutz,nice job.

-- sawdust the bigger the pile the bigger my smile-larry,so cal.

View CaptainKlutz's profile

CaptainKlutz

1507 posts in 1916 days


#14 posted 06-17-2019 01:26 AM

You folks are making me blush!
Didn’t expect so many ‘wow’ reactions over some wood with little color added on shop furniture?
Thanks for the comments, LJ folks are best.

PS – It’s not too pretty to use: Was repairing a greasy/dirty mountain bike gear issue on top of the saw table yesterday. LOL

-- I'm an engineer not a woodworker, but I can randomly find useful tools and furniture inside a pile of lumber!

View pottz's profile

pottz

5558 posts in 1406 days


#15 posted 06-17-2019 01:40 AM



You folks are making me blush!
Didn t expect so many wow reactions over some wood with little color added on shop furniture?
Thanks for the comments, LJ folks are best.

PS – It s not too pretty to use: Was repairing a greasy/dirty mountain bike gear issue on top of the saw table yesterday. LOL

- CaptainKlutz


ha- why not that’s what it’s for right,if it’s too pretty to use it’s worthless in my opinion.hey shop furniture can be beautiful as long as your not afraid to f-it up.

-- sawdust the bigger the pile the bigger my smile-larry,so cal.

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