Well, first off, this is my maiden voyage for blogging. Hope it works. I will basically detail the construction of my router table that is built into the fence rail system of my Ridgid tablesaw.
I started by purchasing an 18”x30”x5/8” piece of baltic birch plywood from WoodCraft. I then cut that piece to 15”x27” which fits inside my rails snugly. Next I attached some red oak strips to the outside edges and back with some glue and later screwed those together. This basically created a frame and helped stiffen things a bit. I attached with 1/4” bolts front and back of each rail…....to do this I measured down from the cast iron deck to the top and bottom of the rail slot, transfered these measurements to the oak strips and drilled a centered hole at all 4 corners. I then attached with washers and nuts which pulls things tight and really stiffens things up. For light duty work I haven’t had any trouble with stability. However, if I am doing more than a simple light profile, I place a roller stand under the deck. Works pretty well.
I then took the base off my router and placed it on top to mark out the holes. Drilled and countersunk them and attached the base to the underneath side. To keep from kneeling down all the time, I can lightly loosen the rail bolts, slide away from the iron deck (past the outside corner bolts) and rotate upward to access the base. A little slow, but saves my knees!
Because I measured carefully against the iron deck and things are flush, I can use the factory tablesaw fence for the saw and router. Just remember, attach a strip of wood to the router side of the fence. Aluminum is not very good on router bits (haven’t done it yet, but only a matter of time!!!)
Anyway, hope this helps, if there are any additional questions, let me know. It is not too tough, and I got it put together in about 30 minutes. A picture is located in my projects file (small scrap wood projects)
-- Measuring twice and cutting once only works if you read the tape correctly!