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15K views 31 replies 16 participants last post by  GaryCN 
#1 ·
Getting this project off to a late start on Lumberjocks

Well, It's been a long time since I have posted anything on here, and I figured that since I have already started a new project that isn't complete yet, this would be the perfect time.

For the past couple of years, I have been wanting to build a router table ala Norm. Well, my birthday was last friday (March 27) and my wife was asking me what I wanted. Well, long story short, I started out with a couple sheets of 3/4" oak plywood, and a sheet of MDF. This past weekend, I spent some time in the shop ripping the plywood based on my own drawn out plans on graph paper based on various versions of the table that I researched on the Internet. I've spent a lot of time researching everyones tips on building to finishing, materials for the top, bracing, the fence, dust collection, and the list goes on and on.

I got most of the carcas completed, minus the drawers and face frame, and just completed laminating the top (2 - 3/4 sheets of mdf glued together) on both sides. This was my first time ever laminating with formica, so I was a bit worried I would mess it up, but everything turned out great. I used black formica and it looks excellent. I have trimmed up the excess laminate on each side, and am ready to install my oak framing around the table top.

One quick note. For those that do not have any of the Kreg pocket hole jigs, they are AWESOME. I have never really used one before, so when I got one last week for my birthday, I had to try it out. It is the most usefull tool I have ever used. I'll have to do a review on the jig soon, and some awesome clamps that Harbor freight had on clearance that work great.

So far, I am pleased with the results of the table build, but still have a long way to go. I will get some pictures of the router table up from this point forward on construction starting tomorrow (camera out of batteries).
 
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#4 ·
Jamie it is nice to see you posting again. I have to agree with Karson. It would be nice to see some pictures of the process. I have one of these on my to-do list as well so following yours is going to be interesting.
 
#7 ·
Karson.. I love that saying.. I know, I know, I need to get some pictures. I'll have them posted tonight. I really have missed you guys and the community of Lumberjocks.

Oldskoolmodder.. I have the kreg jig, or as it is also called the Kreg DIY jig. The entire carcass of the router table was built using Titebond III wood glue and pocket holes. I have to say that I probably could jump up and down on the carcass and it wouldn't even budge or creak. I was a bit worried that I would crack some of the plywood on the edges, but with a little caution, it all went smoothly.

Every day I look forward to working on it to get 'er done.
 
#8 ·
Pictures and current progress

Well this one is for Karson. Here are some pics of the new router table currently in construction.

This picture is just a view from the front. The top consists of 2 pieces of 3/4" MDF glued together sandwiched between a top and bottom layer of black formica. I have not added the solid oak molding around the table top yet, but it's ready to go. Probably will happen tomorrow, along with the face frame for the cabinet carcass. The top will be a bit over 25" X 36" when the oak molding is on. By the way, the top is not mounted yet. I just placed it onto the cabinet for the pics. You can see the drawer fronts inside the cabinet. The fence is in pieces right now and has not been assembled yet. It is made of MDF. I still have to get some laminate on it, drill some holes, create the dust collection port and fence faces, etc. I am waiting on my t-track to arrive also. If you look closely, you can see the pocket holes in the carcass on the inside I did with the Kreg jig. Awesome.. Just awesome!
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Here is the router table at an angle. The PVC piping on the table will attach to the back of the cabinet for dust collection. The side port off of the PVC pipe will be attached to the fence dust port with clear corrigated flexible tubing. Please excuse the mess in the shop. I am going to try to get most of the shop cleaned up this weekend. This was the first time I had ever laminated anything, and it turned out great. The sawdust on the table makes it look like it is messed up in the pictures, so please ignore this. You can see on the top front part of the side, there is a 3/4" X 3" piece of solid oak that runs across the front for additional stability. I did the same on the bottom of the front and back of the cabinet to keep the table from sagging any. I should get quite a few years out of this one.
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In this picture you can see the dust collection port (4") on the back of the cabinet, and the back of the fence. The only visible pocket holes are 8 on the back. The rest were done within the cabinet where the drawers will hide them. I wanted to do these on the inside also, but there wasn't enough room within the side drawer areas to screw them in properly. I will hopefully plug the ones on the back tomorrow.
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This is a distance shot of the router table. The small PVC fitting will go into the fence dust port to attach the hose. I placed small temporary castors on the bottom to move the cabinet around until I can get some good locking castors.
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This is the cabinet dust collection area that will house the router. I kind of followed what seems to be the standard for this. I still have some final cleanup and sanding to perform before finishing.
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Here is a closer pic of the fence back. I still have a lot of work to do to get this sucker finished. You can see the table saw that I restored a while back with the Delta T2 fence in the background. Still works like a charm.
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This is a pic to show that the fence has not been assembled yet.
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Just another pic from the back of the cabinet.
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I'll start keeping up with the pics during the progress of the project. I have just been so anxious to get this thing done to start using it.
 
#9 ·
Thanks for the pictures, Jamie. I know that it is difficult to keep a documentary going when you are in the middle of a project since you have to break your routine and concentration (not to mention take time later to post them). But a construction post like this does convey a lot of useful information and is fun for the rest of us to follow your progress.

By the way this is looking pretty good. It certainly is an inspiration for me, personally, to get out in the shop and start on my version.
 
#16 ·
More progress

Well guys, Once again, an update to the Router table. got quite a bit done today. overall I think it is going to take about 3 - 4 weeks given the time I have in the shop. Enjoy!!!

Rear Dust port installed (not permanently yet, still have to put some poly on the finish). The base plate allows me to attach a different port setup if needed like a 90 deg angle, etc.
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Fence is now partially finished. Installed the braces and dust port with a little glue and 1 1/4" recessed screws.
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Here are some shots of the face frame. The cabinet is stained with Red Oak, and the face frame in Golden Oak. I wanted a bit of contrast. The drawers and door will be done in Red Oak also, and the table top frame in Golden Oak. The face frame is 3/4" wide by 1/2" deep. I used the cross cut side of the oak on the front so that the figuring would show. You can't really see it in the pictures, but it looks awesome.
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And some pictures of the router door. I used spline miters for the door, and Red Oak stain on it to contrast against the Golden Oak stain on the face frame.
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Here is the top where I am installing the 1" X 2" oak frame around it. I made sure that the cross cuts were shown on top for the figuring. I tried to get some good shots of the figuring in the oak, so hopefully you can see it. I should have wet it down a bit.
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This final shot is just of the cabinet side to show the contrast between the two stains.
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The next few pics show the current state of my shop. When you are caught in the moment and really want to get a project done, this is what happens. I really, really, really need to get her cleaned up.
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For those that remember, a year ago or so I ran into some 1" oak trim that was being thrown away from a resturant. All of the solid oak used in this project is from that.

Hopefully some more progress this week!!!
 
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