Table saw (new Delta) router wing (mistakes included) ***UPDATE*** (w/ pics)

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Project by Shawn posted 09-09-2014 03:38 PM 3718 views 7 times favorited 9 comments Add to Favorites Watch

I started not to post this because I butchered the top with my plunge router. I figured I would show my mistakes and all. It might help someone else. This is my first “shop tool/jig” project so bare that in mind while looking. If there is anything you see that I can improve please let me know. I started by removing the original metal table saw extension wing and spreader bar.

I used all the existing holes in the fence rails and cast iron table. I just used 2×4 material for my frame to give me more meat for when I enclose the router with a box for dust control. For the top I used 3/4 inch birch ply as a base and glued a thin melamine type board to it.

(-Side note: I picked up about 30+ pieces of all different types of sheet ply and wood at a discount hardware store in their “defect” stack where I live for $30 and the top I used on this project came from that pile. It was used as a cover sheet from one of their suppliers.)
Once I had the frame built and the table glued up I pre-drilled and screwed the table in place. Then I located and measured for the table saw’s existing holes and transferred those measurements to the new router table and installed it using the table saw hardware.

Once it was in place I had to make sure it was perfectly flat and true to the table saw and figure out where to mount the router.

I used a hand plane very carefully and a manual hand sander to get it just right. Next I cut out a hole in the table just big enough for the router to slip into.

After the hole was cut out I then decided on a router plate size and made it from the same stuff as the top since I had plenty to spare. Now, here is where I got tired and should have stopped for the day, but I just HAD to finish the top so I could insert the plate. I set my plunge router to the dept of the melamine and routed out the size of the plate I made. I locked the plunge while I was using it and forgot to unlock it twice when I set it down to the side (big disappointment), but that didn’t stop me. I didn’t use a guide and tried to free hand the outline of the plate (I have done this before with good success), but I was tired and trying to finish for the day so I got sloppy. If there was any point during this whole project to take my time this would be that point, but I didn’t and here is the result of that…

Like I said, I started not to post this project b/c at this point I was so upset with what I had just done to my nice, clean top, but I kept going and in the end all I have to do is turn the table over (not the frame) and glue in another piece of melamine. Not a huge deal, but not necessary either. Once I actually leveled the plate all the imperfections didn’t matter. To level the plate (no pic) I have 6 small round head screws under the plate just screwed into the table. The router is secured to the shop made plate with it’s original screws (I removed the router’s factory plate). I then counter sank 4 screws into the plate to give it a nice firm fit. To remove the plate and router I have to remove 4 screws.

The router can be removed through the hole with the plate attached, but I had to take off the router handles. I have a Skil router mounted to this table and it is working out rather nicely. I can change the bit from the table top by unlocking the router mount and extending it to it’s highest capacity (this is done by reaching under the table, not bad at all). To set the router height I unlock the router mount, move it up or down and lock it back, then use the fine adjustment to get it just right.

I plan to build a box to enclose it with a door and also a shop made lift.

The fence was pretty simple to make, it’s just a couple pieces of 3/4 ply and some 45’s to hold it together. I did add some pieces of wood to the back between the 45’s to make a couple storage compartments (to hold the wrench or router bits while I’m working). I will be adding an adjustable sacrificial fence front, a t-track to the top portion, adjustable slides in the table top and a miter slot (just waiting on that stuff to come in).


I received the parts to finish my router table and fence and I also took the time to re-do the table top. This time I didn’t cut out a plate insert. I just attached the router to the underside of the top and I will eventually purchase a nice insert. I am pleased with the way everything turned out. The t-track is attached to a permanent piece on the top portion of the fence and the lower part of the fence is adjustable for different size router bits. I added a miter track to the table top to accept my table saw miter gauge (I had to remove the little wheel, though). I purchased the Rockler router table accessory kit which includes 3 feather boards (2 for the fence and 1 for the table), the knobs and t-bolts to connect them, and a 2 1/2” dust port. I also purchased a router bit guard that attaches to the t-track, which I’m not sure how well I like it due to the fact that I can’t adjust it as low as I would like and I think that’s because of where I installed the t-track. Overall I’m happy with it and best of all I can change anything without too much hassle.

Sorry for the long post, but thanks for looking!

-- -Shawn

9 comments so far

View dlgWoodWork's profile


159 posts in 3172 days

#1 posted 09-09-2014 04:36 PM

Looks good. Don’t shy away from posting mistakes either. We all make them, some are brave enough to show them. I think it helps in two way. It can help someone avoid it and it can help someone with a way to fix their mistake. I have the same setup in my table saw, you will enjoy this.

One thing to make sure of, since you removed the metal wing and metal spreader, double check your fence is parallel with the blade when all the way out to the right. It would be easier to find a slight error now and fix it, then when you cut a large panel and realize its not square.

Thanks for posting this.

-- Check out my projects and videos

View Ttier315's profile


58 posts in 959 days

#2 posted 09-09-2014 11:24 PM

Great job, mistakes and all. I have the same saw and I’ve been debating whether to build my router table where the right extension table is or build a dedicated router table. Still not sure what to do but the more ideas I see, the easier it will be to decide. Thanks for posting

-- Tom T, upstate NY

View Tugboater78's profile


2431 posts in 1609 days

#3 posted 09-10-2014 03:03 AM

Needing to do the same for my tablesaw but I keep putting it off, I never thought about gluing one of those.panels to plywood to give the slick top. Maybe that is the kick in the pants I needed. Thanks for showing the mistake, it helps to make sure I won’t do the same.

Btw, how do you like that saw? They put one on display at my local blue box recently and I been eyeballing it. J have an old craftsman that does a good job but it is clunky in comparison to a newer one.

-- "....put that handsaw to work and make it earn its keep. - summerfi" <==< JuStiN >==>=->

View DonB's profile


482 posts in 2110 days

#4 posted 09-10-2014 12:08 PM

Shawn: I have a similar setup. My mistake was the last job in making the RT. I routered a place for the track to go. Took two passes. The melamine is so slick my clamps were insufficient to hold the guide in place and I made the strip wider at the left end than the right side. I filled it in and it works fine, but like you, I see it as a glaring mistake. I also was tired at the end of the day in the hot garage. That was before I installed a little AC in the window. Learned, as you did, not to push it when you’re tired – could have been wood pinched in the table saw and eaten it.

-- DonB

View BigDaddyO's profile


135 posts in 2195 days

#5 posted 09-10-2014 12:56 PM

You built yours the same way most people do and the exact thing happened to you that I was afraid of, which is why I build mine differently than most. I’m not a fan of routers myself and only have one because there are some things that only they can do.

is your Router fence attached to the table saw fence at all? just wondering as if you have a micro adjust on your TS fence it makes it really easy to tune in for a perfect cut on the router table.


View fivecodys's profile


566 posts in 1054 days

#6 posted 09-10-2014 08:09 PM

Bob Ross (Joy of Painting) used to say that they are not mistakes but rather Happy Accidents!
We all make them and I appreciate that you are willing to share them.
Looking back, I think that I have had the most fun trying to fix the mistakes I have made.


-- Chem, Central California

View Shawn's profile


51 posts in 1012 days

#7 posted 09-10-2014 09:13 PM

Thanks guys. I’m glad I kept building despite a few mishaps.

Tugboater78: I love the new Delta! I know some folks are partial to the cabinet saws, but this one is just right for me. It is quiet, rolls around great, and affordable. Above all that, it’s a great working saw. I haven’t had any regrets… yet.

BigDaddyO: I’m waiting on the parts to come in attach the fence to the table. It will be adjustable. Of course I will get a good nights rest before I start that process. LOL!

-- -Shawn

View PhillipRCW's profile


382 posts in 682 days

#8 posted 02-03-2015 10:18 PM

I just started using the same saw and was staring the other day at that wing thinking it would make a great router table. Really surprised at how quiet and well it performs. Adding this to my to do list now.

-- Phillip- Measure twice, cut onc.... Hey look, it's rustic.

View PhillipRCW's profile


382 posts in 682 days

#9 posted 03-30-2015 09:24 PM

I had to check back and see your update. I really like the upgrades. I believe I have everything to start this project soon. I just need to decide which router I want.

-- Phillip- Measure twice, cut onc.... Hey look, it's rustic.

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