Router Table Extension -- /dev/random

Router Table Extension

Overview

An extension for my table saw to use the rip fence as part of a router table, as well as a corresponding split fence.

Parts and Tools

Table saw
Router with straight bit
Incra T-Rule, for properly placing the hex nuts
Random orbital sander
Drill
Hex bolts and associated nuts, these matched the square nuts that came with my table saw that the fence's guide slid onto.
Random thinner bolts and nuts to attach the router base to the table
MDF
Very straight pine boards, 3.5" wide by about 1/2" thick
Pine timbers

Construction

Cut a piece of MDF to the desired size(distance between fence guides, and then slightly longer than the guides). Drilled a smaller hole in it, and widened it with the router. Also made 2 small holes for attaching the router's fixed base.

Attached two more pieces of MDF to the sides, and drilled holes for the hex nuts(Not pictured). This was by far the hardest part, since the hex nuts had to be placed perfectly to get everything level and even with the table saw, while still going into the fence guides. It took me several tries even with the t-rule:

Cut some legs from the timbers, to keep pressure off the fence guides, as well as reinforced underside with the leg scraps:

Finally sanded the top completely flush with the table saw's top. It was off by a hair(Not enough to stop the fence, but it would make noise when crossing the table saw/router table boundary) even after all the measuring I had done.

The split fence was incredibly straight forward. Cut two pieces of wood roughly the size of the fence, and then 4 small pieces to act as spacers. Glue it all up and then cut a square area out of one side for the bit to go through (I used the table saw which was less tedious than it sounds):

Conclusion

I'm very pleased with it, for no longer than it took to make:

It's very level, completely flush with the table saw, and does what it is supposed to. I found that trying to use it without featherboards is completely suicidal, and even worse will screw up your cuts. Also I made the fence in such a way that almost all debris goes between those 2 small middle pieces, and it will be really easy to hook up a dust collector when I get one.

Comments(0) 2009-01-29 00:58:10

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