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The Router Table and Cabinet Blog #4: The Construction

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Blog entry by chazmonro posted 02-18-2008 01:02 AM 4049 reads 6 times favorited 7 comments Add to Favorites Watch
« Part 3: Construction Phase 1 (the grid) Part 4 of The Router Table and Cabinet Blog series Part 5: Construction Complete »

Well after… wow 109 days (Holidays), I finally got back to my router table… As you may recall its a woodpeckers right side mount router table that works in conjunction with my incra fence on my table saw and over time the weight of the router caused the top to sag. Well I finally decided to do something about it and build a torsion box to not only put the table top back in the “flat”, but keep it that way. And you know what, it seems to be working quite well… I mean, its DEAD nuts flat. So that actually makes me pretty happy. Here are some pics.

The first picture is the grid installed to the table top, the grid is 2.5 inches, so the screws were 3 inches long, I put a screw at every intersection and a few in various other places…
Grid installed to table top

The second photo shows the piece of Baltic Birch plywood I cut for the under side of the grid… The cutout was refined with a router and a bearing once it was attached to the grid.
Bottom of grid

To make the dado groves I used a jig and a busing on router… this worked quite well, but here is a tip for you guys, baltic birch isn’t uniform, so making it snug for one piece might make the dado actually to small for other pieces… I didn’t know that, Had to rout out a couple of the dados twice… what a PITA.
Dado jig in action

This next photo is of the assembled case, which I might say turned out quite well for my first case… I used a nail gun and glue to hold it together, and my daughter helped me put the adjustable feet on it… she’s only three, but she seems to really like sawdust and power tools…
Case with helper

Finally for this installment of my blog… I built a couple simple sliding shelves… or are they drawers? I have no idea, but they work great and they took all of about one minute to make. I’m going to put some holes in them to hold the router bits… Ok, so there is a lot of room for router bits… yeah, I only have a dozen at the moment, but I hope that will change someday.
Sliding shelves

So next comes the doors and the cabinet door… Any suggestions on how to attach drawer fronts to those sliding shelf/drawers?

-- Chuck [Elgin, IL]



7 comments so far

View GaryK's profile

GaryK

10262 posts in 3456 days


#1 posted 02-18-2008 01:12 AM

That’s one beefy looking top on that table! Nice

-- Gary - Never pass up the opportunity to make a mistake look like you planned it that way - Tyler, TX

View Todd A. Clippinger's profile

Todd A. Clippinger

8901 posts in 3567 days


#2 posted 02-18-2008 01:34 AM

Nice!

That is the same table saw that I started with. They are a pretty decent saw, at least mine was. It was a very smooth cutting machine.

-- Todd A. Clippinger, Montana, http://americancraftsmanworkshop.com

View Blake's profile

Blake

3442 posts in 3342 days


#3 posted 02-18-2008 02:29 AM

Sweet router table. You got the most important thing down: its dead flat. Great storage and base too. I’m an Incra nut myself and just finished my router table too. You will get a kick out of your new table.

-- Happy woodworking! http://www.openarmsphotography.com

View jeffthewoodwacker's profile

jeffthewoodwacker

603 posts in 3271 days


#4 posted 02-18-2008 02:57 AM

You could cut a dado in the drawer front and glue it to the drawer. A finger hole in the drawer front would be a simple way to open and close the drawer.

-- Those that say it can't be done should not interrupt those who are doing it.

View Scott Bryan's profile

Scott Bryan

27251 posts in 3289 days


#5 posted 02-18-2008 04:51 AM

Wonderful table. One of these is on my to-do list and I wouldn’t have considered the torsion box if it weren’t for this post. Thanks for the help.

-- Challenges are what make life interesting; overcoming them is what makes life meaningful- Joshua Marine

View chazmonro's profile

chazmonro

43 posts in 3339 days


#6 posted 02-18-2008 05:05 AM

I talked to the incra guys at the wood show, and the tops sag over time because of the weight of the router lifts, the demo guys swap tables all the time, my solution was a torsion box, that way I could keep the incra table, though you could probably build a table top out of baltic birch and not run into the sagging issue… the incra tops are mdf and they cut a dado into them for an aluminum miter guage chanel that weakens the top, so it flexes over time and sags. The guys at my local hardwood shop made one out of baltic birch, 2 inches thick, and theirs has never sagged…. though thier setup is a free standing unit, not a right side companion to the table saw.

-- Chuck [Elgin, IL]

View Kipster's profile

Kipster

1076 posts in 3220 days


#7 posted 02-18-2008 05:18 AM

Very nice. THis will last fore ever… no sagging going on here.

I like the idea to attach the drawer front to the siding bottom. Simple and practical. Enjoy your ne tool.

-- Kip Northern Illinois ( If you don't know where your goin any road will take you there) George Harrison

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