ROUTER TABLE This

Plans NOW® www.PlansNOW.com

ultimate Router Table

his plan design includes just about every wish-list item we could think of for a shop-built router table. But there Tare a few features in particular that really stand out.

Large, thick top - It’s big enough to handle most workpieces, and it’s equipped with a miter track for holding jigs and other accessories. T-track fence system - Includes a micro-adjust feature for precision cuts and also plays a key part in the built- in dust collection system. Storage - Below the table, the stout base adds ample storage. And there are casters that make it easy to move the router table around your shop.

Finally, it’s made from inexpensive MDF. That means this router table won’t cost you much to build.

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1 3 9 A Sides (4) 15/4 x 30 - /4 MDF OVERALL DIMENSIONS: 35"D x 36"W x 40 ⁄16"H 1 1 3 B Backs (2) 8/2 x 29/4 - /4 MDF 1 1 3 C Tops (2) 8/2 x 14/2 - /4 MDF DUST AND CHIPS ARE MICRO-ADJUSTER 1 3 3 CHANNELED THROUGH LETS YOU FINE-TUNE D Bottoms (2) 8/2 x 17/16 - /4 MDF FENCE AND TABLE FOR FENCE POSITION 3 3 EASY COLLECTION E Doors (2) 9 x 29/4 - /4 MDF 3 3 F Shelves (4) 7/8 x 14 - /4 MDF 1 1 3 G Base Sides (4) 5/4 x 15/4 - /4 MDF BLAST GATE CONTROLS DUST COLLECTION 1 3 H Base Fronts (2) 5/4 x 9 - /4 MDF THROUGH FENCE OR 3 3 UNDER TABLE I Cleats (1) /4 x /4 - 84 rgh. 1 1 1 J Corner Blocks (2) 1/2 x 3/2 - 5/8 1 1 3 K Sides (2) 13/2 x 15/2 - /4 MDF 1 3 L Back (1) 13 x 15/2 - /4 MDF FENCE FACE CAN 1 3 M Top/Bottom (2) 13 x 14/4 - /4 MDF BE CUSTOMIZED TO 3 3 MATCH BIT SIZE FLIP-UP TABLE N Edging (2) /4 x /4 - 13 EXTENDS CAPACITY 1 13 3 O Long Side (1) 2/2 x 8 /16 - /4 MDF OF TABLE AND FENCE 1 1 13 3 LARGE 1 ⁄2"-THICK P Short Side (1) 2/2 x 5 /16 - /4 MDF TABLE RESISTS 1 1 3 Q Long Back (1) 2/2 x 19/4 - /4 MDF SAGGING 1 3 3 R Short Back (1) 2/2 x 14 /4 - /4 MDF BUILT-IN DUST 1 1 3 S End (1) 2/2 x 4/2 - /4 MDF SYSTEM COLLECTS CHIPS 9 1 T Bottom (1) 9 /16 x 20 - /4 Hdbd. FROM BELOW 3 3 1 THE TABLE U Blast Gate (1) 3/4 x 3/4 - /4 Hdbd. WHEN FENCE IS 3 V Support Plate (1) /4 x 6 - 13 REMOVED 1 W Drawer Fronts/Backs (6) /2 x 4 - 10 PIVOTING ARM 1 SUPPORTS X Drawer Sides (6) /2 x 4 - 13 TABLE 1 1 1 EXTENSION Y Drawer Bottoms (3) 10/2 x 12/2 - /4 Hdbd. 11 3 3 Z False Fronts (3) 4 /16 x 12 /4 - /4 MDF 1 AA Table Core (1) 24 x 36 - 1/2 MDF BB Table Skins (2) 24 x 36 - Plastic Laminate 1 1 CC Table Extension Core (1) 9/2 x 11 - 1/2 MDF POWER SWITCH 1 PROVIDES DD Table Extension Skins (2) 9/2 x 11 - Plas. Lam. HANDY ACCESS 3 1 EE Support Arm (1) /4 x 1/2 - 12 TO ROUTER 1 3 CONTROL FF Fence Base (1) 9/2 x 21 - /4 MDF 1 5 3 GG Fence Runners (2) /4 x /16 - 4/4 3 NOTE: HH Fence Sides (2) 2 x 8 - /4 MDF JOINERY II Fence Back (1) 2 x 3 - 3/ MDF REINFORCED 4 WITH SCREWS 1 1 JJ Fence Cap (1) 4/2 x 8 - /4 Acrylic FOR EASY 3 ASSEMBLY KK Fence Fronts (2) /4 x 3 - 28 3 1 LL Fence Top (1) /4 x 1/8 - 28

Hardware

1 1 • (24) #6 x 1/2 Fh Woodscrews • (8) ⁄4"-20 Hex Lock Nuts 1 1 • (64) #8 x 1/4 Fh Woodscrews • (8) ⁄4"-20 x 2" Carriage Bolts 1 • (22) #8 x 1/2 Fh Woodscrews • (6) #8 x 1" Fh Woodscrews THREE • (4) #8 x 2 Fh Woodscrews • (3pr.) 12" Full-Ext. Drawer Slides w/Screws DRAWERS 1 ADD AMPLE • (2) 4" Fixed Casters • (2) 1⁄2" Hinges w/Screws STORAGE 3 1 3 1 • (8) ⁄8"-16 x 1⁄2" Carriage Bolts • (1) ⁄8"-16 x 4⁄2" Fh Machine Screw FOR BITS, 3 3 JIGS, AND • (10) ⁄8" Flat Washers • (2) ⁄8"-16 Nylon Lock Nuts ACCESSORIES 3 • (10) ⁄8"-16 Hex Nuts • (2) Leg Levelers w/Nylon Inserts LARGE CASTERS 3 1 MAKE MOVING THE • (2) ⁄8"-16 Leg Levelers • (4) ⁄4"-20 T-Nuts ROUTER TABLE EASY 3 1 1 — JUST TILT AND GO • (2) ⁄8"-16 T-Nuts • (4) ⁄4"-20 x 1⁄2" Fh Machine Screws 3 5 • (2) ⁄8"-16 Acorn Nuts • (5) #6 x /8" Fh Woodscrews 1 1 1 • (16) ⁄4"-dia. Shelf Pins • (2) ⁄4"-20 x 1⁄4" Hex Bolts 1 LEG LEVELERS KEEP • (5) 4" Drawer/Door Pulls w/Screws • (2) ⁄4"-20 Locking Levers NOTE: RABBET TABLE STEADY ON 1 1 • (2) 1/2" x 30" Piano Hinges w/Screws • (1) ⁄4"-20 Coupling Nut JOINERY AND UNEVEN FLOORS INEXPENSIVE MDF • (2) Magnetic Catches w/Screws • (1) Micro-Adjuster SAVES TIME AND 5 • (9) #8 x /8" Fh Woodscrews • (2) 48" Mini T-Track w/Screws MONEY 1 • (1) 2/2" Dust Port • (1) 36" Aluminum Miter Track w/Screws 1 • (8) ⁄4" Flat Washers • (1) Power Switch

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ss100_018.indd100_018.indd 1919 66/10/2008/10/2008 10:39:4010:39:40 AMAM 4#/4 #6 x 1!/2" Fh B SIDE WOODSCREW (15!/4" x 30") FIGURE C 1#/4 A a. b. 1 1#/4 !/4 BACK 1!/4 TOP 1!/2 3!/2 #/4 A TOP SIDE FRONT C A TOP VIEW VIEW (8!/2" x 14!/2") A TOP VIEW SIDE B !/4 BACK 2&/8 (8!/2" x 29!/4") !/2 2 A #/4 BACK 2 SIDE BOTTOM A 1!/2 c. 6#/4

2!/8 1!/2 BOTTOM D NOTE: 1" DIA. PRE-DRILL NOTE: ALL PARTS ARE 1!/4 HOLES FOR MADE FROM #/4" MDF CASTERS 1!%/16 (FIGURE 4) SIDE D BACK BOTTOM (8!/2" x 17#/16") side storage 1#/4 BOTTOM VIEW really just simple MDF boxes. because the back rests on the bot- Towers Before you cut the parts to size, tom, as illustrated in Figure 1a. there are two things I want to point Joinery. The construction of the The base is divided into several out. The fi rst is the shape of the towers is pretty simple — just rab- sections: two towers, two bases, bottom piece. It’s designed to proj- bet joints reinforced with screws. and a drawer cabinet. This keeps ect from the back. This will place You’ll fi nd the specifi cs in Fig- the construction straightforward. the casters in just the right spot to ures 1b and 1c. This means you Once the sections are complete, roll the table around without it tip- won’t need to use a lot of clamps they are bolted together. ping over (Bottom View). or spend time waiting for glue to The base has two main func- The second thing is that the back dry. A table saw with a dado blade tions. First, it’s meant to provide is shorter than the sides. This is makes quick work of the task. ample support for the tabletop. FIGURE To do that, it’s designed in an “H” MAGNETIC shape. This rigid assembly absorbs 2 1#/4 CATCH vibration and helps keep the top from sagging. 3&/8 3 The second function of the base a. FRONT C VIEW DOOR L is to provide handy storage space. PULL TOWER It doesn’t take long to acquire quite SIDE SHELF a collection of router bits, jigs, and MAGNETIC SHELF STRIKE accessories. Now you can organize PIN them in one location. #/8" Make it Mobile. As I men- E DOOR tioned before, the router table is NOTE: TOWER DOORS F AND SHELVES ARE SHELVES built mostly out of MDF. And that MADE FROM #/4" MDF (7#/8" x 14") means it’s heavy. So I added a pair of heavy-duty casters that allows the router table to be rolled around DOOR STRIKE your shop easily. HINGE TOWERS #/16 1!/2" CONTINUOUS HINGE I began by building the two side E DOOR DOOR towers, as in Figure 1. They are PULL DOOR !/2" ROUNDOVER (9" x 29#/4") b. TOP VIEW

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ss100_020.indd100_020.indd 2020 66/10/2008/10/2008 10:40:2210:40:22 AMAM I installed the screws through FIGURE CLEATS I the top and bottom to hide the 3 #8 x 1!/4" screw heads, as shown in Figures CLEATS Fh SCREW J I I 1b and 1c. This puts the screw CORNER BLOCK G holes close to the edge. To avoid BASE SIDE G splitting the sides, you’ll want to 5!/4 take care to drill accurately sized H G BASE 15!/4 BASE SIDE pilot and shank holes. FRONT H Before assembling the towers, I BASE !/2 NOTE: CLEATS ARE FRONT also took the time to drill holes for 9 I MADE FROM #/4"-THICK 4 CLEAT HARDWOOD. BASE PARTS shelf pins and a connector piece (#/4" x 4!/2") ARE MADE FROM #/4" MDF you’ll make later. Since the tow- TOWER ers are narrow, it’s easier to do this TOP VIEW BOTTOM TOWER BOTTOM now, as in Figure 1. 1!/4 I Doors. The next pieces to make CORNER BLOCK &/8 are the doors (Figure 2). They’re J C 5!/8 I nothing more than MDF panels. L 3!/2 CORNER G G H BLOCK I BASE They have a roundover on each FRONT SIDE long edge and a shallow rabbet on VIEW 4!/2 &/8 one edge to accommodate a piano #/4 G hinge, as shown in Figure 2b. #/4 SIDE VIEW Shelves. Inside the towers, I a. CLEATS BASE FRONT b. c. added a set of shelves (Figure 2). They’re just cut to fi t from MDF and rest on the pins. The construction of the base when you tilt the router table back takes a slightly different approach and move it around the shop. BASES than the tower. Instead of rabbets, Cleats. After cutting the base Each tower sits on a short base the base is assembled with glue, pieces to size, you can make the section. The base conceals a caster screws, and cleats, as in Figure cleats, as shown in Figures 3a, 3b and a leg leveler, as illustrated in 3. The cleats also make it easy to and 3c. Since access is tight, it’s a Figure 4. The fi xed caster makes attach the base to the tower. good idea to pre-drill the screw moving the router table a snap. Taper. The base sides have a holes for attaching the cleats to the And the leveler allows the router slight taper cut along the bottom base and tower. Then attach the table to remain wobble-free on edge, as you can see in Figure 3. cleats to each base piece before glu- uneven shop fl oors. This detail provides clearance ing the whole assembly together. At this point, you can attach the #/8" x 1!/2" TOWER BOTTOM CARRIAGE bases to the towers (Figure 3). 4 BOLT BASE Leg Leveler. I also made a cor- FRONT ner block for each base unit, as in Figure 4. The corner block holds a #/8" ACORN leg leveler. These non-skid levelers LEVELER NUT keep the MDF bases from touch-

T-NUT ing the ﬂ oor where they could get #/8" HEX NUT dinged up or absorb moisture. CORNER BLOCK a. CROSS SECTION Once you have the corner block screwed and glued in place, mark and drill an access hole in the CARRIAGE CUT CORNER BOLT b. AWAY BLOCK tower bottom so you can adjust TOWER BOTTOM the leveler from above, as in Figure 4" FIXED CASTER 1. To adjust the height easily with #/8"-16 a socket wrench, an acorn nut is CASTER T-NUT #8 x 1!/4" Fh WOODSCREWS glued on the end of the leveler with USED TO ATTACH CORNER BLOCK epoxy, as illustrated in Figure 4. Casters. All that’s left is to attach #/8"-16 x 5" NON-SKID the casters to the tower bottom. LEVELER CROSS SECTION These are held in place with carriage bolts, washers, and nuts.

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ss100_020.indd100_020.indd 2121 66/10/2008/10/2008 10:40:4210:40:42 AMAM DRAWER CASE TOP DRAWER (13 x 14!/4 L CASE BACK " ") (13 x 15!/2 FIGURE !/2" M " ") 5 ROUNDOVER completing 2 a. #/4 N EDGING The Base (#/4 " x 13") K !/4 FOUR !/4"-DIA. 1!/4 Turning the individual towers !/4 HOLES FOR MOUNTING K into a rock-solid base is the goal CASE TO DRAWER CASE TOWERS CASE SIDE (13!/2 x 15!/2 of the next stage of construction. TOP BACK " ") To do this, the towers are joined M together by a center drawer case N DRAWER CASE 1!/4 BOTTOM CASE BOTTOM and a hardwood support plate. (13" x 14!/4") And you’ll also create part of the 3 dust collection system. DRAWER CASE #6 x 1!/2" Fh SIDE VIEW WOODSCREW The ﬁ rst thing to do is build the drawer case. As you can see in FRONT VIEW b. #/4 c. !/2" Figure 5, it’s made the same way ROUNDOVER NOTE: CASE as the towers — with rabbets and CASE SIDES, BACK, TOP, AND !/4 TOP M BOTTOM ARE #/4" MDF, screws. But there are some differ- !/4 EDGING IS #/4"-THICK CASE SIDE HARDWOOD ences I want to point out. K N Joinery. The main difference is EDGING SIDE VIEW the rabbets are cut into the top and bottom and screwed together from Edging. Another difference is on an extra-wide blank. The wide the sides, as in Figures 5a and 5b. the edging applied to the top and blank is safer and easier to con- Here again, the idea is to hide bottom of the case. It creates a trol. Then I ripped the edging to the screw heads when the towers recessed opening that the drawer width at the table saw. Finally, it’s are attached on either side. I also fronts will ﬁ t into later on, as you attached to the case after assembly. drilled holes in the case sides for can see in Figure 5c. Now, you’ll set aside the drawer attaching the case to the towers, as To make the rounded edging, case for the time being to work on shown in Figure 5. I started by routing a roundover part of the dust collection system. You’ll need to have it built before FIGURE BLAST GATE LONG SIDE (3#/4" x 3#/4") the base can be assembled. 6 SHORT SIDE (2!/2" x 8!#/16") (2!/2" x 5!#/16") U O DUST COLLECTION NOTE: BACKS AND SIDES ARE P MADE FROM #/4" MDF. SUPPORT %/8" PLATE IS #/4" -THICK HARDWOOD. LONG BACK One of the things that sets this BOX BOTTOM AND BLAST GATE (2!/2" x 19!/4") RADIUS ARE !/4" HARDBOARD router table apart from most isn’t Q readily apparent — the dust collec- 6 tion system. With a single connec- DUST BOTTOM (9(/16" x 20") tion point, the table collects chips T and dust from either the fence or around the router motor. The key #8 x %/8" to this is the simple L-shaped box Fh SCREW V C SUPPORT L you see in Figure 6. PLATE R The box wraps around one of PRE-DRILL SHORT BACK 13 (FIGURE 7) (2!/2" x 14#/4") the towers so that it’s easy to access NOTE: CUT NOTCH TO FIT AROUND DUST the dust port for attaching a shop a. 2 COLLECTION BOX vacuum or dust collector hose. S Simple Construction. I began END LONG BACK (2!/2" x 4!/2") DUST BOTTOM by making the box pieces. You’ll T b. P S BLAST notice that dadoes in the long and #/8 GATE O 1 !/4 short side are sized to hold a ⁄4" C 2!/4" DIA. L hardboard blast gate (Figure 6b). !/2 V Then I routed a chamfer on the TOP !/4 SHORT BACK leading edges to soften them and VIEW 4!/4 to act as a funnel to direct chips #8 x 1!/4" Fh WOODSCREW TOP VIEW from below the table into the box.

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ss100_022.indd100_022.indd 2222 66/10/2008/10/2008 10:41:1910:41:19 AMAM #8 x 1!/4" Fh WOODSCREW NOTE: DRIVE SCREW #8 x 2" Fh FIGURE AT ANGLE TO ATTACH WOODSCREWS Assembling the box begins with 7 DUST BOX the two L-shaped corner assemblies. The important thing here is that the assemblies are square. a. FRONT Then you can cut and add the end. VIEW TOWER The last piece to add is the bottom. SIDE SUPPORT PLATE This is a piece of hardboard with a DRAWER CASE SIDE hole drilled in it to attach a plastic dust port, as in Figure 6a. When the box is assembled, you CARRIAGE BOLT can make a blast gate to fi t the front opening (Figure 6). #8 x 1!/4" Fh Support Plate. To center the box WOODSCREW under the table, I added a support DUST plate, as shown in Figure 6. It’s sized SHORT to match the width of the drawer BACK case and has a centered notch that TOWER BACK fi ts around the dust box. SUPPORT !/4" x 2" PLATE CARRIAGE Assembly. At this point, you’re !/4" HEX BOLT STOP NUT ready to assemble the base sec- W/ WASHER tions. Figure 7 shows you how the TOWER SIDE TOP VIEW NOTE: ATTACH DRAWER CASE pieces go together. I used clamps to b. FLUSH WITH BACK AND keep the drawer case aligned with BOTTOM OF TOWER CASE each tower. Then it’s just a mat- ter of using the mounting holes in DRAWERS details in Figure 8a. Then after the drawer case as a guide to drill All that’s left to complete the base cutting a groove for the drawer matching holes in each tower, as is to make the drawers that fi t in bottom, they can be glued up. shown in 7a. The drawer case can the center case. And combined The drawers slide on full- now be bolted to the towers with with the side towers, it provides a extension slides. Just be sure to carriage bolts, washers, and nuts. lot of versatile storage options. attach the slides at the bottom of the The next step is to attach the sup- As you can see in Figure 8, drawer. This way, they’ll miss the port plate at the top of the towers. It’s the three drawers are identical. hardware used to assemble the case. mounted with screws (Figure 7b). To keep things simple, they’re Once the drawers are in place, Then you can fi t the dust box into assembled with tongue and dado you can cut and attach the false 1 the opening and screw it to the left joinery. This is an easy joint to cut fronts. I sized them for an ⁄8" gap tower with a screw from the back. at the table saw. You can fi nd the on all edges (Figure 8b).

!/4 8 !/4 a. DRAWER BACK NOTE: DRAWER FRONTS, BACKS, AND SIDES ARE !/2"-THICK HARDWOOD, W FALSE FRONTS ARE #/4" MDF Z #8 x 1" Fh WOODSCREW DRAWER SIDE (4" x 13") X 1!/2 !/8 Y X DRAWER BACK W W W DRAWER FRONT (4" x 10") FALSE DRAWER FRONT FALSE W X FRONT X TOP VIEW !/4

Y !/4 CL

!/8 C Y DRAWER BOTTOM 12" DRAWER L (10!/2" x 12!/2" - !/4" Hdbd.) SLIDE SIDE ASSEMBLY VIEW DRAWER FALSE FRONT DRAWER PULL Z (4!!/16" x 12#/4") b.

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ss100_022.indd100_022.indd 2323 66/10/2008/10/2008 10:41:3810:41:38 AMAM 3#/4 NOTE: REFER TO SHOP SHORT b. #/4" DIA. CUTS (PAGE 10 ) TO CUT FIGURE OPENING FOR BLAST GATE 9 BLAST 3 laminated GATE 3#/4 INSERT 3&/8 !/4 3

Tabletop TABLE SKIN BB TOP VIEW Now that the base is complete, TABLE CORES you can turn your attention to AA the top and fence. The tabletop is where all the action takes place. 9#/4 The router is mounted to an insert plate in the middle. And the fence CL is positioned using a set of T-tracks BB 24 in the top. There’s even an alumi- 36 Download a num miter track that lets you use a step-by-step miter gauge or other accessories. a. SIDE VIEW BLAST article to install Flip-Up Extension. This table INSERT GATE BB a router insert also has a unique feature — a !/2 AA plate as well small table extension at the back, as AA as plans for shown in Figure 10. This small fl ip- the optional up table provides more capacity door and back to position the fence farther away Multi-Layer Top. To accom- in Figure 9. The key when doing panel. Go to from the bit. And it drops down plish these goals, I started by mak- this is to keep the assembly fl at. I our website: when I don’t need it. ing the top and extension. You can bonded the two layers with spray ShopNotes.com In building this section of the see how it’s made in Figures 9 and contact cement. It works fast and I router table you have a few goals. 10. In a nutshell, each table is a don’t have to mess with clamps. First, the tabletop should be as fl at four-layer sandwich. Laminate on the Outside. A and smooth as possible. In addi- In the middle are two layers of layer of plastic laminate on the CUT AND FILE 3 !/2" OFF TABLE tion, the table should be rigid to ⁄4" MDF. This creates a fl at, rigid top and bottom completes the END OF MINI T-TRACK support the weight of the router base. And the MDF helps to absorb sandwich and provides a smooth, without sagging over time. Finally, vibration from the router for I also wanted a good way to help cleaner cuts. I started by cutting control the dust and chips gener- the pieces of MDF to size and then ated by the router. gluing them together, as shown

FIGURE DD TABLE EXTENSION 10 #/4" MINI T-TRACK SKINS (2) FILE SMALL 1!/2 CHAMFERS 1!/2" RADIUS 9!/2 11

1" MITER 1!/2" HINGE TRACK C C { Blast Gate Flush. In this TABLE EXTENSION position, dust and chips are 2!/16 CORES collected from below the table. 3 12%/8 PRE-DRILL #/8"-DIA. HOLE COUNTERSINK FOR #/8" Fh MACHINE SCREW (SEE FIGURE 12)

1 TOP VIEW MINI T-TRACK #/4 !/2 #/8 T-TRACK MITER TABLE TABLE TRACK EXTENSION #8 x %/8" #6 x %/8" Fh WOODSCREW Fh WOODSCREWS

CENTER HINGE { Flip It Up. Slip the gate into the SIDE VIEW HINGE KNUCKLE a. b. ON SEAM c. BACK VIEW notches vertically to allow the fence to collect debris above the table.

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ss100_024.indd100_024.indd 2424 66/10/2008/10/2008 10:42:1510:42:15 AMAM durable worksurface. When the 11 laminate is in place, you can trim it ﬂ ush with edges of the MDF using a router and ﬂ ush trim bit. USE BLAST GATE TO Miter Groove. With the top ALIGN TOP AND BASE #8 x 1!/2" Fh (DETAIL ‘a’) glued up, you’re ready to start WOODSCREW adding a few details. One of the things to add is a miter slot for a miter gauge. The groove is sized to hold an aluminum miter track, as POWER shown in Figures 10 and 10a. SWITCH

Two Openings. Next, you’ll #8 x 3!/2" Fh need to create a pair of openings. WOODSCREW The smaller opening is used to a. SIDE VIEW channel dust and chips to a shop LOWER TOP USING BLAST GATE AS b. vacuum. The larger opening holds ALIGNMENT GUIDE MARK AND NOTCH a router insert plate. TOP DUST BOX I started with the smaller open- ASSEMBLY TO FIT HINGE ing. And you can learn how it’s BLAST GATE made on page 10. As for the open- IN VERTICAL ing for the insert plate, I used a POSITION template that came with the plate. Don’t worry, if you don’t have a template, there’s a step-by-step article for this on our website: The secret to perfect alignment is here is to align the notches in the www.ShopNotes.com. to use a template. You can read top with the dust box (Figure 11a). T-Track. There’s one other item more about it on page 10. You’ll also need to make a mortise to add to the top — the mini The T-track can then be cut to in the dust box to accommodate the T-track used to position the fence. fi t. Each piece is trimmed back at hinge, as in Figure 11b. But before making the grooves for the front end, as shown in the left The fi nal additions to the top are the T-track, I attached the table margin on previous page 6. This the support arm and power switch extension to the top with hinges. notch creates a space for the hex (Figure 12). The arm holds the } Design Option. A hand-held router is perfect for bolts in the fence to engage in the extension level with the tabletop. A back panel and making the grooves. However, the T-track when you set it in place. A pair of leg levelers allows you to a door muffl e the wide grooves in the table need to Attach the Table. At this point, fi ne-tune the extension so that it’s sound of the router. line up with the narrow grooves you can screw the top to the base level with the top. The switch is You can fi nd plans in the fence you’ll build later. (Figure 11). The important thing simply screwed to the side tower. on our website.

12 TOP VIEW #/8" x 4!/2" TABLE Fh MACHINE TOP SCREW NYLON LEVELER SPACER

!!/32" DIA. #/8" DIA. SUPPORT ARM #/8" I.D. x !/2" !/2 NYLON 3 SPACER a.

LEVELER WITH THREADED NYLON INSERT SUPPORT ARM E E (#/4" x 1!/2" - 12") ATTACH DUST PORT TO BOTTOM #/8" LOCKING OF DUST BOX HEX NUT W/WASHER

ss100_024.indd100_024.indd 2525 66/10/2008/10/2008 10:44:0810:44:08 AMAM micro-adjustable Fence

At this point, the heavy work of Second, I added a T-track to the building the router table is com- fence face. This allows me to attach plete. All that remains is the fence. bit guards, featherboards, or stop NOTE: PLANE RUNNERS TO FIT INSIDE I know a few woodworkers who blocks. The face of this fence is a MINI T-TRACK only use a straight board with a single, fl at piece. This one-piece GG notch for a router table fence. And design isn’t likely to go out of align- while that works, I wanted to add ment or catch on the workpiece as { Fine Tuning. This micro- a few more features. split fences sometimes do. adjuster makes it easy to precisely As I said before, the fence is also Micro-Adjuster. A third feature tweak the fence setting. a crucial part of the dust collection I want to highlight is the micro- system built into the router table. adjuster you see in the inset photo adjustments to the fence position. A channel in the back directs chips at right. And I can’t tell how much It eliminates the “tap-and-hope“ into the dust box (photo above). hassle this saves in making fi ne method I’d been using for years. From the Bottom Up. To make FIGURE the fence, I started with the base. MINI T-TRACK 13 1%/16 21 c. 1!/2 After cutting it to overall size, I 3 BASE routed grooves in the bottom edge STEP 1: LAYOUT BLANK BASE BLANK to hold hardwood runners, as 7!/4 shown in the upper portion of Fig- 4!/4 CUT OUT NOTCH FOR MICRO- ure 13. These runners will guide 1!/2 a. ADJUSTER the fence in the T-track mounted CL #/4 into the tabletop. NOTE: DRILL !/4"-DIA. REFER TO SHOP HOLES THROUGH SHORTCUTS, To rout the grooves, I used CENTER OF DADO PAGE 10 the same template I used for the BASE BLANK 9!/2 7!/4 T-track grooves. But this time, I FILE A !/2" installed a guide bushing with a CHAMFER AFTER 1 NOTE: BLANK IS CUTTING NOTCH ⁄4"-dia. straight bit. You can fi nd MADE FROM #/4" MDF b. the details on page 10. !/4" LEVER LOCK KNOB Cut to Shape. Once this is done, STEP 2: ASSEMBLE !/4" it’s time for some shaping. There BASE COMPONENTS CONNECTOR NUT RUNNER CONNECTOR are several details to take care of (%/16" x 4#/4") NUT GG on the base. The fi rst is cutting the FF !/2"-DIA. x 1!/2"-DEEP fence base to its fi nal “delta-wing” FENCE HOLE BASE (DETAIL ‘c’) shape. I did this at the band saw and then fi led the edges smooth. A MICRO- RUNNER roundover along the back softens (%/16" x 3!/4") GG ADJUSTER INSTALL FENCE BASE the top edges, as illustrated in the NOTE: GUIDE STRIP WIDTH AND MICRO-ADJUSTER IS CUT TO FIT MINI T-TRACK INTO T-TRACK lower portion of Figure 13. (MARGIN DETAIL ABOVE) TO LOCATE NUT !/4" x 1!/4" HEX HEAD BOLT c.

ss100_026.indd100_026.indd 2626 66/10/2008/10/2008 10:45:0510:45:05 AMAM FENCE CAP (4!/2" x 8" - !/4" ACRYLIC) FIGURE #6 x %/8" Fh J J FENCE SIDE WOODSCREW Next, I cut a small notch in one 14 (2" x 8" ) side to accommodate the micro- HH adjust mechanism for the fence. This is detailed in Figure 13a. To NOTE: FENCE provide better access to the micro- a. BACK AND SIDES FENCE BACK #/8 MADE FROM HH (2" x 3" ) adjuster, there’s a wide chamfer #/4" MDF on the back side of the fence base I I FENCE (Figure 13b). This can be done with SIDE a hand saw and a fi le. FENCE CAP A Cutout. The next step is to make a cutout for the dust and chip FENCE BASE collection. Here again, I turned to FF the band saw to do the job. FENCE BASE There are also a couple holes drilled in the top for the locking BACK VIEW handles that secure the fence. #8 x 1!/2" Fh Runners. Then you can make WOODSCREW some runners to fi t the grooves in the bottom of the base and the work smoothly, everything needs The chute is attached to the base T-track. The trouble is the groove to be aligned perfectly. Thankfully, with glue and screws. The top of in the top of the T-track is slightly there’s an easy way to do this. the chute is a piece of acrylic and is 1 wider than the ⁄4" grooves in the You can see how it’s done in Fig- attached with screws (Figure 14a). base. To make the runners, start by ure 13c. Drill an oversize hole in the Front of the Fence. All that’s planing a wide piece of hardwood edge of the fence base. Then thread left to complete the fence is the to fi t the T-track (left margin on the the coupling nut on the micro- three-piece front section. Figure 15 previous page 8). Then cut a small adjuster. I “buttered” the outside of has all the details on how it goes shallow rabbet on each side to fi t the nut with some epoxy and then together. The front face is attached the groove in the fence base. Aim locked the adjuster into the T-track, with machine screws. This way for a smooth sliding fi t with no pressing the nut into the hole. This you can make several faces to play. Then, rip the runners to size. keeps everything in alignment accommodate different size bits. Micro-Adjuster. With the run- until the epoxy hardens. At last, you’re ready to drop ners glued in, you can set the fence Dust Channel. Next, I assem- your router into place and fi re it in place to install the micro-adjuster. bled the sides and back of the up. Then you can enjoy the results The adjuster threads into a cou- fence. The back edge is rounded to of your efforts with smooth, accu- pling nut in the base. And for it to match the base (Figure 14). rate cuts every time.

FIGURE FENCE BASE FRONT TOP ASSEMBLY 15 (#/4" x 1!/8" - 28") !/4" L L THREADED MINI T-TRACK T-NUT WITH SCREWS

2 #8 x 1!/4" Fh WOODSCREW C L 1!/2 8

a. L L FENCE KK FRONT FENCE FRONT KK (#/4" x 3" - 28) !/8 KK #/4"-DIA. NOTE: MAKE EXTRA FENCE FRONT COUNTERBORE FENCE FACES WITH (#/4" x 3" - 28") DUST FOR T-NUT DIFFERENT SIZE NOTCH NOTCHES !/4" x 1!/2" Fh MACHINE !/8" x !/8" SCREW DUST RELIEF NOTCH ENTIRE LENGTH { Handy Storage. You can lock END VIEW the fence to the extension and fold NOTE: FENCE FRONTS AND FENCE TOP ARE #/4"-THICK HARDWOOD it away when you don’t need it.

ss100_026.indd100_026.indd 2727 66/10/2008/10/2008 10:45:4010:45:40 AMAM Making the Blast Gate Pocket A simple blast gate and opening in you can cut out the waste with a slide in vertically so dust and chips our router tabletop will allow jig saw. I cleaned up the cut edge can be pulled through the fence you to control how dust and chips with a fi le and some sandpaper. opening. A hand saw and chisel are channeled to a shop vacuum. Notches. Other details to add to make quick work of this task. The And you’ll fi nd creating the open- the opening are a pair of notches important thing here is to match ing is a simple process. at the front of the opening (Step 5). the width of the notch to the thick- Template. I started by laying out The notches allow the blast gate to ness of the blast gate. TEMPLATE the location of the opening as you NOTE: TEMPLATE MADE FROM #/4"-THICK HARDWOOD can see in the drawing at right. To #/4"-DIA. x !/2"-DEEP TABLE FINGER HOLE TOP create a clean, accurate opening, I STEP 1: GLUE UP made a simple template to guide a BLAST TEMPLATE AROUND !/2"-DIA. GATE BLAST GATE FOR A PATTERN router and pattern bit. PERFECT FIT ROUTER BIT The template is made by wrap- SAME ping some hardwood scraps THICKNESS AS STEP 2: BLAST GATE around the blast gate you made ROUT OUTSIDE EDGE OF OPENING AND earlier. I attached the template to DRILL FINGER HOLE ATTACH TEMPLATE the top with double-sided tape. TO TABLE WITH After setting the bit depth to DOUBLE-SIDED TAPE match the thickness of the blast gate, rout around the inside edge of the template (Step 1). Then to provide a fi nger hole for removing the TOP VIEW blast gate, use a Forstner bit to drill STEP 5: a shallow counterbore along the CUT OUT NOTCHES back edge (Step 2). Opening. In Steps 3 and 4, you CUT OUT can see how the opening is made. OPENING STEP 3: DRILL WITHSTEP JIG SAW 4: CUT OUT THICKNESS After drilling some starter holes, FOUR STARTER HOLES OPENING WITH JIG SAW OF INSERT SQUARE UP CORNERS Routing Grooves for Fence The T-track in the router table Table Grooves. After attach- Fence Grooves. To rout the needs to be perfectly aligned ing the template to the table and grooves in the fence base, I used 3 3 with the runners in the fence for extension, I used a ⁄4"-dia. pattern a ⁄4" O.D. guide bushing and a 1 everything to operate smoothly. bit to rout the T-track grooves, as ⁄4" straight bit, as in detail ‘b.’ To accomplish this, I turned to the you can see in the detail ‘a.’ It’s a The bushing guarantees that the template shown in the drawing good idea to rout the grooves in grooves in the fence are centered below and a hand-held router. several, shallow passes. over the grooves in the tabletop. ENDS TABLE (3" x 6!/2") NOTE: GROOVES SAME TEMPLATE FENCE USED TO ROUT GROOVES ROUT GROOVE FENCE GROOVES NOTE: TEMPLATE IN SEVERAL MADE FROM a. PASSES #/4"-THICK HARDWOOD FENCE BASE

SIDES (3" x 29#/4") TABLE FRONT VIEW

!/4"-DIA. b. STRAIGHT BIT ATTACH TEMPLATE TO TABLE AND EXTENSION WITH DOUBLE-SIDED INSTALL #/4" O.D. TAPE GUIDE BUSHING FENCE BASE FRONT VIEW

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