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Bass Bully's Router Table #2: Making the Substrate

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Blog entry by BassBully posted 03-23-2007 08:46 PM 1710 reads 0 times favorited 4 comments Add to Favorites Watch
« Part 1: Research Part 2 of Bass Bully's Router Table series Part 3: Applying Formica Laminate to Substrate »

Last weekend I began making the substrate for the router table top. The substrate was created by gluing together two pieces of 3/4” thick Baltic Birch plywood measuring 28” x 32”.

I started cutting one of the two pieces from one sheet of 4’ x 8’ Baltic Birch. Since I do not have an assistant to help cut the plywood on my table saw, I laid the sheet on two saw horses and made the initial cuts of the first piece using a circular saw guided along a straight edged clamp. I made the initial cuts a little larger than necessary because I later squared them up with the table saw.

Like the first piece of the substrate, I cut the second piece a little larger than necessary but this time I didn’t square it off with the table saw. I would do this later using the router after the two pieces were laminated together. I chose to square it up in this manner because glue’s slippery nature makes it difficult trying to align two identical pieces together.

I then sandwiched a layer of glue between the two pieces making sure that the larger piece was properly placed so that I could trim off its edges with a flush trim router bit after the glue dried. I put clamps on the two pieces where I could and then laid Olympic weights on top of the rest of the wood. I did this all on my table saw because it is flat and sturdy.

Gluing Substrate Material

After the glue had set up, I put the substrate back on the saw horses with the larger half of the substrate on top. I ran the flush trim router bit along the sides to make everything equal.

Trimming Substrate

This weekend I will round off the corners with my oscillating spindle/belt sander and apply the counter top laminate on both sides. Hopefully, I can also install the t-track and miter slot hardware and have the top completed. I have pictures but need to get them off of my camera, and I need to find an online place to store the photos. I’ll also try to get that done this weekend as well.

-- There are three types of people in the world, those who can count and those who can't!



4 comments so far

View Karson's profile

Karson

34916 posts in 3155 days


#1 posted 03-23-2007 09:00 PM

BB did you use screws to sandwich them together or just Glue.

I used Glue and screws and I don’t know where the screws are so I’m unable to cut a slot without possibility running into a screw.

I also made braces 3 layers of Baltic Birch and screwed it to the table so it wouldn’t sag in the middle after hanging the router on it.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware karson_morrison@bigfoot.com †

View BassBully's profile

BassBully

259 posts in 2852 days


#2 posted 03-23-2007 09:06 PM

Karson,

I did not use screws to laminate the pieces together. Braces will be one of the last things I do because I don’t have the cabinet designed yet. The top is going to hinge off of the cabinet for accessibility and I’m not sure where the cabinet partitions will lye until I’m done.

Do you think a metal detector will help you find the screw locations accurately enough?

-- There are three types of people in the world, those who can count and those who can't!

View Karson's profile

Karson

34916 posts in 3155 days


#3 posted 03-23-2007 09:32 PM

Yes it might. I’ve got an Incra fence on the router, so I’ve not noticed a real need for using a slot. But, if I had one I’d probably use it.

I haven’t tried the metal detector route. I’ve used it on one board that a friend gave to me to plane. (right after hitting a broken off screw. Only chipped two teeth on my planer. (Carbide inserts)

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware karson_morrison@bigfoot.com †

View Matt's profile

Matt

119 posts in 3171 days


#4 posted 03-24-2007 02:54 AM

Hi Bass,

A great freebie sight for storing photos online so everyone can get a look at your progress is www.flickr.com . Myself and I do believe a few others here on LJ use it. I just had a listener to my podcast ask about making a router table and I’m sure your project would be a great example of “how to”.

-- Straight grains & sharp blades

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