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Project Information

I was nervous about working the cast iron wing myself, but I had made up my mind to build an extension for the router anyhow. I figured I'd take a shot at grinding the iron since I was replacing it anyhow. I traced a plastic router insert on the table and used the drill press to drill a series of small relief holes around the inside perimter. I then used a jig saw and some light filing to finish the opening. I had to use an angle grinder to grind under the wing so as to allow the router plate to be flush with the bottom. That took forever and the metal shavings rusted in the driveway. Lesson learned there. I cut the wooden zero clearence insert from maple and sanded it flush. Still haven't raised the bit to make the hole as its late and others are sleeping. I attached my piece of junk laminate router as I found out my Dewalt was too big to not be in the way of the angle adjustment wheel on the saw. I'm without a jointer, so my end goal is to attach a jointing fence to the tablesaw fence t-track and use this router pretty much only for that function.

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Your braver than I am Jeff. Will be interesting to see it in action.
 

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Good job Jeff. Time to make smoke.
 

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Quite inventive Jeff. Let us know how it works out.

My recent issue of ShopNotes, (Vol.16, issue 96, pg46) has an interesting article called "Jointing on the Tablesaw". They made an auxillary fence out of MDF that clamps to the existing fence. The 1st half is plain but the second half (output of the blade side) has a piece of laminate glued on. This acts as an offset jointer table would. The blade is raised into a sacrificial area of the fence cutting just 1/16" on each pass of the project board. I hope you can get an idea of this as I cannot download the article or scan the pics. And I'm all thumbs at this time with Sketch-up. Maybe somebody else can help further.
Anyhow, this looks like a doable application for you. Should also work with the router.
 

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I bet that took a long time, Wow!
 

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I love jigs and mods, but this one takes it. Yeow! I did not know you could do that. BTW I have my router table as a wing of the table saw so I can share the fence etc. I like it. I would like to see how it works for you.

Steve
 

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That's inventive, Jeff. We wait to see how it works. But, I'll bet it works just fine.
 

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It made me wince to read the title. LOL. Then I looked at how much it costs to replace the wing on my saw…I'd give it a rip too. Nothing ventured, nothing gained…however, the new wing costs the same as the router wing, so that may change it…my jointer is in the way anyhow. Nice! LOL
 

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Solid, show us some dust.
 

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Looks like you have some tool making skills rising to the surface,good job.Hey by the way is that a grizzly table saw? I am looking hard at buying a grizzly saw,If thats what you have how do you like it?
 

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Pigpen: Yep, that's a Grizzly 1023. Love it. If it was stolen today, I'd rebuy. Not a Powermatic, but very reasonable for a non-pro. Had to wire the shop for 220V. They now package it with a router wing for pretty cheap. Under $1000. Wasn't an option when I got mine 2 years ago. The router wing from Grizzly costs $200 so if you think you'll want one, get it up front.

Dadoo: I remember that issue and jointing jig. I built one a while back and they work great. I attached it to the T-track on my Aux fence when needed.

I'm working up a plan for an outfeed table with a router insert as well. I have a router plate that needs a home and I figure the table saw outfeed table works as well as any. I'll have to design a removeable fence, but there's tons of designs out there for that.
 

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AFTER USE UPDATE: If anyone's seen pics of some of the other shop mods I've made, they'll notice this wing has been removed. I think the idea is sound, I just didn't execute it well. The inserts were a pain to make and weren't able to be readily changed to accomodate bit sizes. In the end, I have opted for a more traditional shop made router wing. Check my projects for that post, if desired. I'd love to know if anyone has made this idea function well.
 

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I agree with the others on this, You are a brave man, but the end results look promising, good job Mate!
 

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Thanks Robert. I again would advise to steer clear of this plan. I knew I would buy or build a traditional router wing in the event this idea flopped, so there was not much down side. The wing was going to be obsolete if it didn't work. I'm not a metal worker. Perhaps others can find a better way to machine the cast iron. It was pain for me. A lot of grinding.
 
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