I built a router table which is attached to my Mafell Erika table saw. In this instructable I'm going to cover how I built the fence for my router table. Since the router table is integrated into the table saw, the router fence can be mounted to the rip fence of the table saw.
Step 1: Plans
The fence is made up of a number of smaller parts. To make the cutting and assembly more efficient I starte with a Sketchup Plan. You can download it from my blog.
Step 2: Main Structure
I start by gluing the parts for the main structure. What's important is to check, that it's really square, since this it's almost impossible to correct this afterwards.
To get the distance between the supporting boards right, I'm using the mounting plate as a spacer. To prevent it from being glued on by accident, I wrap the corners with packing tape.
Step 3: Front
The front is made of resin coated plywood. It get's a T-track at the top which is used as tool mount.
The plywood is cut at the table saw. On one short side they get a bevel of 45° and on the top I'm cutting a rebate for the T-track.
Finall everything is screwed to the base structure.
Step 4: Mounting Plate
To screw the router fence to the rip fence of the table saw I'm adding a mounting plate to the base structure.
The angle for the support blocks is taken directly from the work piece. Then I'm stacking all four of them together with painters tape and cut them on the bandsaw. Then it's time for some drilling and screwing.
Step 5: Mounting Holes
The router fence is mounted to the rip fence of the table saw using M6 machine screws. The mounting plates do get two 6 mm holes for this. To get the nuts an even surface when tightened, I flatten the area around the hole with a forstner bit and then drill through with a 6 mm drill bit.
Step 6: First Try
In a perfect world the project would be finished now. But during the first assembly I realized that the fence is not square to the table top. I had a closer look and realized, that the extension table and the table saw are not exactly at the same hight. A second problem is the fact, that there's a 2 mm gap between the mounting plate and the rip fence.
Step 7: Fixing the Errors
I have been using screws for most of the assembly to be able to fix this kind of mistakes.
For the extension table I had to remove the rails and add some layers of paper to raise it.
To lower the mounting plate, I took the support blocks to the belt sander and shortened them.
I had to repeat this procedure two times. But in the end I got a perfectly square router table fence.
Step 8: Dust Collection
Since a router produces a lot of dust, dust collection is a must. In my project it's a simple box with an opening at the front to receive the dust and a hole at the top for the shop vac.
Step 9: Finished
And that's the finished router table fence. It's very sturdy and absolutely square. The first use was to produce 60 m of crown molding, which went very well.