As part of the build night this last weekend for our local makerspace (the Rabbit Hole), it was decided they needed a router table. I was familiar with the concept, so I took the opportunity to help build one, with some maker design elements.
Step 1: Design Idea
First step was to get a rough Idea of what we wanted built. A quick sketch, and some scrounging for materials were in order.
Step 2: Key Feature
The maker movement is all about reuse and recycle, as well as electronics. So for our build we used a scrap PCB to build our surface plate. Some blue painters tape, a few marks to align holes to the router, and we can start cutting.
Step 3: Cut and Drill
Using the available tools, we cut the outside of the plate with a Dremel and drill pressed the holes for the bolts.
Step 4: Frame Table
Once the hard part was done, we put the frame together with 2x4s cut to length of the top sheet and a height that is comfortable to stand at (3'6"). Drill and screw the boards together and it is roughed in ready for mounting the surface and the router.
Step 5: Add Sacrificial Plate
Since the design was simple and round, we just needed a simple recess to mount the plate to the table and keep the height of the table surface. We set the height of the router to the height of the PCB, Drew a circle in the center of the table using the PCB, and routed inside the circle.
Step 6: Finish Build
Once in the rough state, the last steps are to drill the holes for the router to mount on, stabilize the legs. and mount the router. A key feature is to allow room for the bit to be changeable from above, so we had to route the center hole a little bigger to allow the wrench in.
Step 7: Final Notes
This build is complete and usable as it is. There are several things that can ( and probably will) be added.
1. The sacrificial surface needs to be adjustable to a small degree. Some screws pushing from underneath should allow adjustment.
2. -A rail system will help guide the work through the router. A small fence can be added quickly and bolted through and adjustable slot on either side of the router bit.- DONE!
3. A miter guage track would be a welcome addition.
4. A dust port would be nice to attach a shop vacuum, and keep the shop cleaner.
Step 8: Full Video
The full video is posted above. Thanks to the Rabbit Hole, Addie & Whisker (the Tymkrs), Tim Massaro, and Ryan Anderson who helped in the build.
Step 9: But Wait There's More!
We had some adjustments to make to improve the build.
1. Part of the screws that hold the plate on were above the surface, so we recessed them further with an inexpensive countersink bit. We verified its flushness with a combination square.
2. It was difficult to get down to turn off the router from underneath, so we mounted a switch in the leg at knee height to interrupt the flow of electricity. (Luckily we had the Dremel Multi-Max and flush cutting blade donated to the makerspace).
3. A rip fence was needed to help with guiding material into the router bit. We settled on building one that included 2 ratchet bar clamps, with a completely removable fence. This served 2 purposes, the fence and a built in material holding tabletop that is quickly moved out of the way.
Step 10: More Video
Peppered throughout this video its the additional features to the router table. Thanks again to the Tymkrs to capturing the video and to John Vriezen for this week's additional help.