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.