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I'm building a router table and I'm using 2 sheets of mdf that have been glued together for the top. My plan was to cut the hole for the insert by using my plunge router with a 1/2" bit at the corners and then finish the cut with my shiny new Bosch jigsaw. My problem is that the mdf is 1 1/2" thick and my 1/2" bit only as a 1 1/4" cutting depth capacity. Can I make the 1 1/4" cuts and then lower the bit in the router to expose more of the bit and finish the cuts? Is there a better way to do this? Thanks!!
 

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Yes, maybe.

If the shank on the bit was long enough to allow the extra 1/4" without the collet hitting the top surface, then yes. I would probably lower the bit about 3/8" deeper on each successive cut.

So this is for the smaller hole that is all the way through for the router. Not the shallow rabbet that the plate will rest on, right?

Steve
 

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Well Dave
most inserts are only around 3/8" thick so normally I rout down close to 3/8" and then cut the cent out buy going inside the the routed area about 1/2 creating a lip for the insert to set in. You really have to take your time to get the depth just right.
 

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Discussion Starter · #4 ·
Thanks!! My plan was to go all the way through with a hole about 1/2" smaller on all sides than the insert and then go back and rabbet out for the ledge. Jim, the insert plate I have is from Hartville and its 7/16 thick. I was going to make the ledge 1/2" wide and 1/2" deep and then bring the plate up with the leveling screws. Please let me know if I'm doing this wrong. Thanks again!!
 

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Greetings Dave: Sounds like you got the router table whipped. Jim gave you great advice on what you needed to do to complete the job. That's the way I would of done it, too…..lol. There are some good ww on here that know their stuff when it comes to things like this. Happy routing, and enjoy the project…....
 

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Discussion Starter · #9 ·
Thanks again!! I went out this morning to get some contact cement and learned that the glue, mdf,and laminate all need to be at 65 degrees for at least 24 hours, so I have to bring the top in the house and let it sit until tomorrow. I also learned that the piece of laminate that I planned on using is 1/2" too narrow!! Arrrrgh!! So, it looks like I'm off tomorrow to get another piece of laminate. This isn't too bad because I wasn't crazy about the color to begin with.
 

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You can use regular wood glue on Formica if you want. Contact cement inside the house is a little nasty smelling. You would have to come up with some kind of press (a lot of things that weigh a lot) and have to wait several hours for it to dry, but it does not smell bad. Just thought I would throw that in as an option.

Steve
 

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Discussion Starter · #11 ·
Thanks all!! I have the spot for the insert plate cut out and,if I do say so myself, it came out really nice. Plate is nice and snug all the way around. Now all I need to do is drill out the holes for the router and I'm ready to start playing!! Having a little difficulty with this phase since the holes line up VERY close to the insert ring and I'm afraid that the where I need to countersink will sneak into the ring area. Called the vendor (Hartville Tools) and the guy there said to just whittle away a bit of the ring if I need to. Yippee!!!!!!!!!
 
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