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My New Router Table #7: Tedious details... Gettin' there

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Blog entry by Blake posted 2463 days ago 5158 reads 4 times favorited 12 comments Add to Favorites Watch
« Part 6: Finishing Touches Part 7 of My New Router Table series Part 8: A Proud Moment »

Here’s what I have accomplished in the past week or so…

Drawers:
So last time I talked about my drawer construction and my not-so-orthodox method of “biscuit-slotting” them together (the “don’t try this at home, kids” method). I got scolded for that a little, and for good reason. It probably wouldn’t have lasted as long. So I ended up just shooting them full of brads to reinforce them since I figured out that the brads would be hidden by the slides anyway.

By the way, here is how the drawers started out:

So I then I [correctly] biscuit jointed the drawer fronts on to the drawers:

I clamped and Glued (this picture is really just to show off some new clamps I got!):

And Here is the result:

OH MY GAWD! I am glad to have that out of the way. So, what’s next? Finally, time to get that router plate installed. I have been putting this off because I am a little scared. What reason could I possibly have to punch a big hole in a perfectly good table? Oh yea, it’s a router table. Ok, here goes…

I had been agonizing about how to make the template to rout the opening. I have already spent enough money on this project and didn’t want to buy one, plus shipping, etc.

The corners of the plate are rounded to a 1 1/2” radius. Ideally they would have been a radius small enough to match one of my template router bits with bearings. That way I could have just made a rectangle template and the router bit would take care of the radius.

But no, Incra had to get all fancy with their 1 1/2” round corners. So creating that inside radius became the next challence. What I did was drill a hole in a piece of plywood with a 1 1/2” forstner bit and carefully cut away the waste so I was left with four corners around the hole that were barely held together (I wish I had taken a photo of that). Then the four corners easily broke apart.

This next picture is the beginning of the template. The two inside pieces are carefully machined to the length of the plate. For the other dimension (width of the plate) I just slid them together until they contacted the plate, which is sitting in between them. Notice my radiused corner pieces sitting near the corners (which I will insert later):

So now, how to join the parts of the template? Hmmmm, how about… MORE BISCUITS!

Ok, now I know what you are thinking. But I actually saw this in a magazine article so it is legit! I used tape to temporarily hold the joints together and then I made the biscuit slot across both pieces.

Then after I glue in the biscuits I will cut the extra half off and sand the whole thing.

Here is the fully glued up template. Notice the 1 1/2 radius corner pieces which I glued in place:

The corner pieces up close:

So when the glue sets up the next step will be to cut off the biscuit excess and sand the whole thing. I will need to especially sand the insides of the rounded corners because I left it a little tight on purpose. I will test the accuracy of the template on another piece of plywood. I will rout out the opening and see how tight the plate fits. Then if I need to do more sanding I can. Once it is the perfect size I will rout the real thing. Wish me luck.

-- Happy woodworking! http://www.openarmsphotography.com



12 comments so far

View Karson's profile

Karson

34870 posts in 3034 days


#1 posted 2463 days ago

You are going to make two different cuts, right. one to match the router plate and the other to make a shelf for the plate to sit on. You don’t want the stright cut all the way through the new top, right.

I’m sure you knew this, I was just wanting to reconfirm.

Great looking cabinet.

-- 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 odie's profile

odie

1680 posts in 2474 days


#2 posted 2463 days ago

I deleted all I wrote…New Me…I will email you…

-- Odie, Confucius say, "He who laughs at one's self is BUTT of joke". http://woodstermangotwood.blogspot.com/ (my funny blog)

View RAH's profile

RAH

414 posts in 2511 days


#3 posted 2463 days ago

Blake, after the first of the year my main project will be a new router table. you have done a nice job on these blogs with informative detail which I plan to use in building my table. I too have been known to procrastinate when I am unsure of a cut or procedure or just plain scared of the outcome, good to know I’m not alone.

Thanks Ron (RAH)

-- Ron Central, CA

View Blake's profile

Blake

3437 posts in 2508 days


#4 posted 2463 days ago

Karson: Yep. Thanks.

-- Happy woodworking! http://www.openarmsphotography.com

View Blake's profile

Blake

3437 posts in 2508 days


#5 posted 2463 days ago

Hey, check this out! This is similar to what I did. Lamello is selling a similar product to the biscuit but it is a half biscuit with ribs which draw the two parts together.

Their Description:
“Lamello present the Fixo self-clamping biscuit. This biscuit quickens and simplifies the joining of many common woodworking joints, including face frames. A biscuit joiner cuts a groove into both work pieces at the same time. The Fixo biscuit is then inserted into the groove and its unique curved ridges pull the joint together tightly. The joint is now complete with no clamping and no waiting for glue to set. The Fixo is made of a rugged fiberglass reinforced plastic which will not damage cutting tools.”

-- Happy woodworking! http://www.openarmsphotography.com

View mot's profile

mot

4911 posts in 2670 days


#6 posted 2462 days ago

I had Karson’s first thought. You’re doing fine work there, Blake. I like the hardware you chose as well. I remember cutting my first router table insert hole…it does provide some finicky anxiety. Nice blog.

-- You can discover more about a person in an hour of play than in a year of conversation. (Plato)

View Karson's profile

Karson

34870 posts in 3034 days


#7 posted 2462 days ago

Blake: Yes thats one of those things that your know or should know, but it’s a brow slap time when you forget 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 Todd A. Clippinger's profile

Todd A. Clippinger

8773 posts in 2733 days


#8 posted 2462 days ago

Blake, I think it looks pretty good. I am sure you have really learned a lot about furniture and cabinet construction on this one. The shop projects are the perfect way to sharpen these skills.

I think this will serve you well. I am still anxious to see how your dust collection works.

-- Todd A. Clippinger, Montana, http://americancraftsmanworkshop.com

View mrtrim's profile

mrtrim

1696 posts in 2514 days


#9 posted 2462 days ago

you got a great style blake , now me i just bull in and start sawin and chiselin and swearin oops not swearin yet that always comes last. i start gluin parts and viola !! thats when the swearin starts ! all is not lost it makes a heck of a good campfire while i hatch plan B . HEHE

View Dadoo's profile

Dadoo

1764 posts in 2624 days


#10 posted 2461 days ago

Blake…That cabinet is just to fine for a woodshop! But man, I envy you. It really looks sharp. I want to see it finished ya hear?

-- Bob Vila would be so proud of you!

View mot's profile

mot

4911 posts in 2670 days


#11 posted 2461 days ago

Blake, nice find on the Lamello thingies…that would come in pretty handy in certain instances.

-- You can discover more about a person in an hour of play than in a year of conversation. (Plato)

View Blake's profile

Blake

3437 posts in 2508 days


#12 posted 2461 days ago

I wish I had know about them when I made the face frame of the cabinet. That would have saved so much time instead of using half-lap joinery.

-- Happy woodworking! http://www.openarmsphotography.com

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