Harry's new router table and fence design #1: Novel approach to make a cutout for your router lift.

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Blog entry by TheHarr posted 05-20-2012 01:51 AM 7475 reads 8 times favorited 6 comments Add to Favorites Watch
no previous part Part 1 of Harry's new router table and fence design series Part 2: Adjustable router table fence »

I picked up a Jessem FX II router lift a couple of years ago and finally found time to make my 4th router table. This time I took a novel approach to make the cutout using the template as a support frame to increase the thickness of the plywood to 1 1/2”. The 2nd part of this blog illustrates how I made an adjustable fence using 1/2” screws. This is an awesome design that uses epoxy so no welding is needed.

My neighbor likes to take pictures for me so instead of writing a novel, I’ll present this as a photo blog with minimal dialogue. That’s less writing for me and more pictures for you. Pictures tell the story anyway.

I decided on a 3/4” rabbet for my insert so I made 3/4” marks on the underside of the insert and measured the template sides against the marks.

To make sure the sides are exactly the same size, I taped them together and gang cut…........

Oops! I cut them too short, I need to trim the sides to make them longer. Think it can’t be done? See for yourself…..............

Now I glued the template together to make the frame. I am amazed how strong the bond wood glue makes.

Attaching the template to the underside of the router table. The sides are glued & stapled, the side near the miter track was just glued. Don’t want to trash an expensive dado blade.

Cut out the inside blank and trimmed flush to the template with a router. You can see the combined 1 1/2” thickness where the router plate rests. This puts the extra support where it’s needed. (It’s a hot day.)

Cut the rabbet in several passes, working from 1/4” on the first pass up to the final 3/4” cut.

Attached the router table to the table saw and dropped in the router lift. I had to trim up the corners with a laminate trimmer to get the plate to fit—no biggie.

Here’s the underside of the router table with the lift.

That’s it for the router table. Using the template for extra support worked out well. Or was the extra support used as a template? Don’t know the answer to that one. The next entry will be about making the adjustable fence. This fence adjustment works better than I hoped. It’s inexpensive and easy to make and—NO WELDING!
Thanks for your interest.

-- The wood is good.

6 comments so far

View sillac's profile


644 posts in 2760 days

#1 posted 05-20-2012 03:17 AM

Looks like a great router table. I am working on mine right now. My first one and at my age it most likely will be my last, so trying to include all the ideas I can think of. Using a shop made lift, via shop notes as several others here have done, but making a few changes to it that I haven’t seen yet. Also using the kreg insert with levelers. Another thing I have done is put a shop built air sled under it. I will post it when I’m finished.

-- Steve in Oregon,

View b2rtch's profile


4861 posts in 3045 days

#2 posted 05-20-2012 11:25 AM

Good job, looks very good and very strong.
I made a router table once and it sagged in the center.
I just ordered a cast iron one to install on my Unisaw.

-- Bert

View plantek's profile


312 posts in 2795 days

#3 posted 05-23-2012 02:35 AM

Nice job!
Your going to love the lift…
It changed my use of the router table dramatically.
and you cant beat the price.

-- If you want it and it's within reason... It's on it's way!

View Joe Lyddon's profile

Joe Lyddon

10097 posts in 4048 days

#4 posted 05-23-2012 03:28 AM

Very NICE!

Looks Great!

Thank you!

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: ... My Small Gallery:"

View WoodNDust's profile


228 posts in 2102 days

#5 posted 05-02-2014 03:24 AM

Very nice. That’s a Grizzly 1023 table saw, right? I have that one too. And have been thinking about adding a router table. This prompts me to look again look at doing something like this.

View raf2's profile


14 posts in 2349 days

#6 posted 06-17-2016 07:17 PM

Looks good, Your you tube video was also good.

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