As noted in my previous post, the counter tops consist of a layer of MDF topped off with phenolic plywood. T-track runs the length of the countertop and is the means by which the fence system will be held in place. I purchased Woodpecker’s DP (dual purpose) track. The underside has a single centered t-slot that accepts ¼ inch hex bolts. Rather than rout the channel for the t-track, I cut the phenolic ply to fit around the track. Since the track is only ½ inch thick, you have to add a spacer to bring it to counter top level. Here’s a photo to show what I have described (minus the spacer).
With the saw sitting on the installed shelf in the approximate location it will sit, I placed a straight edge against the saw’s fence and extended it over the counter top and made a mark. That is exactly where the front edge of the track must fall. I continued taking precise measurements and then cut the rear pieces of phenolic ply to size. I attached these pieces to the MDF using hot melt glue to hold them in place so I could turn them over and nail them from below. Next, I glued and nailed the spacer for under the t-track alongside the rear phenolic ply. At this stage I placed the unit on top of the cabinet exactly where it would sit and drilled holes precisely where the ¼-20 hex bolts would go. I drilled through the spacer, the MDF and the cabinet tops. I placed bolts in the t-track, slid the t-track in place and assured a snug fit. Now I measured for the front pieces of phenolic ply, cut those and glued and nailed them just as I did the rear pieces. All that was left was to wrap the unit in solid maple and polyurethane the maple.
Next up: The fence system. Hint: Kreg does more than pocket hole jigs.
-- On the eighth day God was back in His woodworking shop! Lenny, East Providence, RI