My original router table was one of my first major projects. I was very pleased with the result and it worked well for years. I recently decided to rebuild my router table, primarily because I screwed up my first router table by installing a cheap phenolic plate that sagged. I had just been using a router screwed directly to the base of the table top and then using a piece of masonite with various sized holes to as a zero clearance insert.
Then I bought a panel raising bit and figured it was time to move to a router plate .. and like usual, cheaping out on the plate caused me grief that ruined my router table.
Here is my highly detailed plan. Note I decided to put the drawers on the back vs the front of the router table based on my shop lay out … stupid idea that made sense at time and can not be explained now.
Here is my old table … I will let you guess which crappy router plate ruined it. In fairness to that company, I have had great luck with their router bits.
So the steps I followed in the first session to create router table cabinet were:
1. Rip plywood sheets into panels
2. Dado the panels on the old router table
3. Create cross braces for top
4. Assemble panel using glues and screws
Step 1 – Cut panels to size
Begin by ripping sheets down into panels
Line up stack of panels – one bottom, three side (L/R/Divider) and one back
Step 2 – Route dados and grooves
I chucked up a plywood bit in the router table and then cut rabbets along the bottom edge of the left right and back pieces to accommodate base. I cut rabbets along the back edge of the left and right panels to accept the back. I cut a dado in the back panel and the base to hold the divider
I then put a row of pocket screws in the non dado ed edges.
Here is the base layout, you can see screws to connect to sides and back panel
Step 3 – Create cross braces for the top.
Since the strength will come from the router table top, I use left over plywood to make four cross braces to hold the cabinet shape and provide an anchor for the top.
Cut cross pieces with RAS
Use pocket screws to attach
Step 4 – Assembly
Apply glue to edges. Given how ply wood drinks up glue, I generally apply a light “sizing” coat, allow it to dry and then apply a second full glue treatment
Attach right, divider and left panels to base, upside down and then set in base and screw in to square up.
Then flip over and screw in cross braces and divider panel and ensure entire assemble is square.
And after two hours, my cabinet base is done
-- Shawn, I ask in order to learn