Router Table #6: Cast(ers) Away

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Blog entry by PurpLev posted 12-26-2009 10:05 PM 4734 reads 3 times favorited 23 comments Add to Favorites Watch
« Part 5: Half Throttle - Cabinet is Framed! Part 6 of Router Table series Part 7: Drawers Under the Weather »

Not much done today, had time to install the casters. had to go the lowes for some lag bolts (5/16) as the casters did not come with it.

I found the casters on eBay for a fantastic price. it’s sold by SES Casters which are here in Massachusetts. total price was ~26 including shipping. they may not be red and shiny – but they are soft, heavy duty, and work fantastic! I highly recommend this seller by any means.

I installed 2 swivel casters on the front of the table, and 2 non swivel casters in the back. when the front casters are locked, there are no wheels that can slide/move in the direction of the feed:


I installed 2 lag bolts into the end of the plywood sides, and 2 bolts with nuts that go through the bottom piece. I’m not too sure about the bolts in the ply-edge as the edge usually doesn’t have much holding power (but I have been pleasantly surprised in the past from screws into ply-edge), but being a physics major – having the plywood sides (which hold the rails and drawers, and all their weight) rest on the casters will create less stress on the bottom piece, and the pocket screws that hold it to the sides. besides, there’s not much pressure on these lag bolts. worst case, I can always remount the casters.

so here it is, in it’s planned location that will/might double work as an outfeed table (just have to figure out how to handle the DC hose in the back of the saw):

router table on casters

the top lays on the cabinet and is very very stable (surprisingly). there is a gap between the top and the right side as it was installed too low, but I can shim that, or fill it with something. I think I’ll mount the top to the cabinet with triangle blocks in each corner (and 2 in the center) to secure it from moving about.

not much done today for lack of time, and the need to drive around for bolts. but at least it took the cabinet off the tablesaw/workbench, which are now back to being functional.

Next I would like to work on the top, and mount the router in it somehow.


-- ㊍ When in doubt - There is no doubt - Go the safer route.

23 comments so far

View degoose's profile


7233 posts in 3351 days

#1 posted 12-26-2009 11:00 PM

One step closer to being able to use it… well done so far… looking very good my friend… I want to see this finished almost as much as I am sure you do…..

-- Don't drink and use power tools @

View PG_Zac's profile


368 posts in 3385 days

#2 posted 12-27-2009 12:21 AM

It’s Looking better each day.

I’m eagerly awaiting the final installment, and the first project.

-- I may be schizophrenic, but at least I have each other.

View Gary Fixler's profile

Gary Fixler

1001 posts in 3378 days

#3 posted 12-27-2009 12:49 AM

Nice! Do you have a router lift, or will you be adjusting height through the router itself?

-- Gary, Los Angeles, video game animator

View PurpLev's profile


8535 posts in 3645 days

#4 posted 12-27-2009 01:09 AM

Thanks guys,

Gary – I bought the Triton 3 1/4 HP router which has a build in lift, and comes with an over the table crank handle. it was either that (a 3 1/4hp motor compared to my 2 1/4 bosch) for $270, or a router lift for my bosch at $300. I went with the larger motor option – which also leaves my bosch free for freehand work.

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View Gary Fixler's profile

Gary Fixler

1001 posts in 3378 days

#5 posted 12-27-2009 01:55 AM

Sounds like the right choice to me.

-- Gary, Los Angeles, video game animator

View blackcherry's profile


3338 posts in 3820 days

#6 posted 12-27-2009 05:43 AM

Wow, your moving right along on this project. A router table come in very handy in any shop which I know you’ll enjoy having. Nice choice on your router selection plenty of power and accessories as well. It won’t take long to fill up all the drawers on your new station, the extra weight come in handy when pushing large stock against the fence. Nice work my friend and may you have a great New Year as well. Blkcherry

View BlankMan's profile


1490 posts in 3350 days

#7 posted 12-27-2009 10:32 AM

Sharon, it’s coming along nicely, looking real good, you’ll be routing in no time.

-- -Curt, Milwaukee, WI

View Tim Dahn's profile

Tim Dahn

1567 posts in 3562 days

#8 posted 12-27-2009 12:38 PM

Coming along very nicely Sharon, I have enjoyed watching the progress. All of the stress on the casters is downward force except when moving and you wont be moving it much so they should be just fine, and thanks for the tip on the company, added them to my favorite sellers list. Are you going to mount the router directly to the top or use a router plate? On the DC from the table saw, when you mount the top can you let it hang over the right side a little to give some more room?

-- Good judgement comes from experience and experience comes from poor judgement.

View PurpLev's profile


8535 posts in 3645 days

#9 posted 12-27-2009 06:38 PM

Thanks for the comments.

Tim- I think I’m going to start by mounting the router directly to the top (the triton router has 2 finger screws to mount it to plates/guides/etc) which means the least amount of routing into the phenolic material, and the smallest affected area. if that fails – I can always open up a through hole to take a plate.

as for the top and extra room for the DC pipe – the top and cabinet are designed to have a 2” overhang on all sides to clamp things (fence,jigs,etc) around if needed. the router table is also lower than the TS (to accommodate the TS miter slots) so I will need to use some auxiliary top on top (ha) of the router table – which I can offset.

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View bigike's profile


4052 posts in 3285 days

#10 posted 12-27-2009 07:12 PM

r u gonna put an insert plate or just mt the router to the top itself? if your not gonna put no plate u don’t have to worry about leveling it but if u have a lift type plate i would go through the hasle of leveling it. either way it’s something cuz if u don’t put a plate and just mt the router u still have to make cutouts of different sizes for the different size bits. main question is plate or no plate?

-- Ike, Big Daddies Woodshop,

View PurpLev's profile


8535 posts in 3645 days

#11 posted 12-28-2009 04:49 PM

Ike- see my previous comment. although I’m considering both options, I think I’ll start by mounting the router directly to the top which means less work for me NOW. I will route a rabbet on the top side of the hole to take inserts for the different sized bits. if I find that this doesn’t work out too well, I’ll cut out an opening for a plate. at the moment,I’m trying to keep work to a minimum for lack of time.

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View HokieMojo's profile


2104 posts in 3725 days

#12 posted 12-28-2009 07:45 PM

Sounds like you made great progress so far. How heavy will the table be when it is complete? I’d be interested to hear how these work with weight on them.

You might remember my blog for lumber and sheet goods storage:

I think I’m a bit over the 300# per wheel capacity of the woodcraft casters I bought. If these work well under some weight, I may consider upgrading to the 8” wheels that your supplier carries, even without the locking capacity. I don’t think the locking capacity matters much on a project as heavy as mine that sits on a level floor and isn’t meant to support running power tools. Keep up the awesome work. I wish I could contribute mroe to your task but I’ve never built (or even used) a real router table. good luck!

View PurpLev's profile


8535 posts in 3645 days

#13 posted 12-28-2009 09:04 PM

Hokie- so far I only have the cabinet and top resting on the casters, and they seem to hold up real well. then again – I still need to add the weight of the router, drawers, 2nd router, and all the stuff that will be in the drawers… I’ll keep you posted when I get to that stage. so far I’m not seeing any issues though.

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View SimonMayport's profile


8 posts in 2660 days

#14 posted 02-09-2011 11:13 AM

It seemed highly functional as it is so plate or no plate is not exactly a priority for now. Nice work I have to say.

-- Simon -

View paulsalisbury's profile


9 posts in 2609 days

#15 posted 06-09-2011 10:02 AM

Another fabulous article by this favorite website. I am keen to build a home conservatory. Any advice would be welcomed.

-- Paul -

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