Im my last project, I built an extension table for my Mafell Erika table saw. In this project I'm going to turn this extension table into a router table. This way I can save the space for an additional router table in my workshop and use the fence of the saw as base for the router fence.
Step 1: 3 Steps to Build the Router Table
In this project I'm going to cut a recess into the table which receives the router. This isn't strictly necessary, but it saves me 10 mm of plunge depth.
Then I cut a round hole into the table to let the router bit come through.
And then I built a sturdy fasting system to fasten the router safely to the board.
Step 2: Router Template for the Recess
To cut the recess I need a template with the shape of the router base. Therefore I simply trace the router base on a piece of MDF. Because the radius of the copy ring is 7 mm bigger than the router bit, I have to add this to the shape. Then I cut the template on the scroll saw.
Step 3: Cut the Recess
Since pencil marks are very hard to see on resin coated plywood I put a strip of masking tape on the board. Then I mark the center and where I want to have the router. The router template is fixed with double sided tape and I'm ready to cut the recess. Because I have to remove 10 mm of wood I do this in two passes.
As you can see on the picture the router fits perfectly into the recess.
Step 4: Create a Circle Jig
To cut the round whole in the table I'm building a simple circle jig with a radius of 50 mm.
- Transfer the holes for the screws from the router base to a piece of plywood.
- Drill and countersink the holes for the screws.
- Fasten the jig to the router
- Cut a hole into the jig with the router.
- Mark the pivot point 50 mm away from the hole in the jig.
- Drill a 2.5 mm hole for the nail which serves as pivot point.
Step 5: Cut a Round Hole Into the Table Top
Now that I have a circle jig for the router I'm drilling a 2.5 mm hole into the table. Then I can put the circle jig with the nail into this hole and then simply route out the circle by turning the router.
Step 6: Base for the Fastening System
The router is fixed to the table using its guide rods. So I need something that clamps this rods to the table. I planed to have the guide rods 4 mm away from the table. This allows me to use simple pieces of 4 mm plywood to build the base.
The second layer of the base is cut at a 45° angle. This makes sure the guide rods cannot move once clamped to the router table.
The pieces are glued in place and the base is screwed to the underside of the router table.
Step 7: Clamping Boards for the Fastening System
With two more pieces of 19 mm plywood the guide rods are clamped to the table. Therefore I drill three 8 mm holes all the way throught the table and the playwood layers. This makes it possible to use 8 mm screws to fix the router in place.
Step 8: What's Next
The router can be safely fixed to the table and the router bit already shows through the table top.
In the next projects I'm going to cover how to build the router fence, the router lift and how to make inserts for the hole in the table.