Router Wing w/ Saddle Fence

  • Advertise with us
Project by USCJeff posted 07-08-2008 06:36 AM 3090 views 6 times favorited 9 comments Add to Favorites Watch

This is my 4th router attempt for this tablesaw wing. All others worked well for a while and let me down when adjustments needed to be made. That being the case, the design was based on being adjustable to those shifts and things that always happen.

The table top is a salvaged 1.5” thick melamine coated electricians bench. It rests on a torsion box made of “2 by” material. There are 8 set screws on the torsion box that are accesible from underneath to level the table with the saw. Four wood screws attach the top to the box and must be loosened to allow the set screws to do their thing.

I extended the tablesaw rails for the left wing by adding angle iron to both sides. The short lengths are strong enough to keep the outer end from lowering with downwards pressure. Machine bolts and nuts secure the angle iron to the torsion box and factory rails.

The fence is great, but it is massive in my small shop when not being used. I plan to eliminate the saddle and add T-track and cam clamps next time I get to Woodzone or Rockler. On that note, I need a miter slot as well. The fence saddle is plywood and the fence itself is MDF. There is a 1.5” MDF support behind the 3/4” adjustable Fence faces. Loosening two wingnuts allow the fence to move as can be seen in the last picture. The saddle is secured to the tablesaw fence using machine bolts into T-Nuts to act as set screws (pic 3). The dust port is set up for a standard Shop-Vac, but I think a 4” port for a DC would work better if anyone decides to do this. I’ve made a couple simpe stop blocks, bit guards, and such for the fences T-track.

The drawer underneath has pegboard in it drilled to accept both 1/4” and 1/2” bits and accesories. The Dewalt 618 router is attached to a Rosseau base plate and wired to a switch. I have a foot pedal that I want to try as well, but I always seem to be hunting for it with my foot. Might have to fasten it down some how.

-- Jeff, South Carolina

9 comments so far

View Callum Kendall's profile

Callum Kendall

1918 posts in 4217 days

#1 posted 07-08-2008 12:45 PM

Looks good!

Thanks for the post


-- For wood working podcasts with a twist check out

View Greg Wurst's profile

Greg Wurst

796 posts in 4346 days

#2 posted 07-08-2008 01:07 PM

Ingenious fence construction there. Not a bad idea attaching it to the table saw fence like that.

-- You're a unique and special person, just like everyone else.

View Bill Akins's profile

Bill Akins

425 posts in 4212 days

#3 posted 07-08-2008 01:51 PM

Great job. I want to attempt that myself one day.

-- Bill from Lithia Springs, GA I love the smell of sawdust in the morning.

View Chris 's profile


1880 posts in 4505 days

#4 posted 07-08-2008 02:07 PM


I think its a great way use what space you have to accomplish what you need…

-- "Everything that is great and inspiring is created by the individual who labors in freedom" -- Albert Einstein

View CharlieM1958's profile


16284 posts in 4732 days

#5 posted 07-08-2008 04:33 PM

Pretty doggone creative!

-- Charlie M. "Woodworking - patience = firewood"

View Texasgaloot's profile


465 posts in 4214 days

#6 posted 07-08-2008 08:03 PM

I’ve wondered about making a sliding fence along my TS fence as well. I think it’s a great idea, and worth pursuing. Especially now that I’ve seen someone else make it work first!

-- There's no tool like an old tool...

View degoose's profile


7258 posts in 3868 days

#7 posted 07-12-2009 06:37 AM

Bloody nice bit of ingenuity.

-- Don't drink and use power tools @

View a1Jim's profile


117722 posts in 4091 days

#8 posted 07-12-2009 06:39 AM

good thinking

View USCJeff's profile


1065 posts in 4582 days

#9 posted 09-14-2011 07:05 AM

I like to go back and update my feelings towards projects after they have seen use over time. Anyone using this idea as a part of their design should know some of the details should be changed. I have upgraded the the standard wing nuts and washers with true knobs. It provides much better control on tightening parts. The standard acrylic piece housing the shop vac attachment was a bad call. It broke under very little abuse. Use decent plastic that won’t crack (having a 4” connection couldn’t hurt either). The MDF moving face fence didn’t stand up well. The points nearest the bits showed wear fairly quickly, which in turn could make the fence not true to each side. A hardwood plywood or a hardboard face would be better suited. Since MDF doesn’t take screws as well, the T-Tracks worked loose. Again, a plywood/hardboard change would help there. Other than that, it has been great. The joints have held to 90 degrees and it’s been fairly simple to set up when ready for it.

-- Jeff, South Carolina

Have your say...

You must be signed in to post the comments.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics