Router table build with lift, plunge feature and clear top

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Project by Mark55 posted 10-07-2014 03:11 PM 3862 views 7 times favorited 9 comments Add to Favorites Watch

This is my latest creation. It is long past due. I have been using a real crude router table I threw together a few years ago. As in many of my projects I wait for the parts to come together to avoid high costs.
The top on this is 1.25” thick clear lexan bullet resistant glass. It was salvaged from a convenience store that was torn down. The piece I used was too scratched up to use for much anything else and I am sure it will get scratched more but the surface is hard flat and smooth. The frame is laminated plywood half lapped and glued together on the joints.
I made many parts on the machine from HDPC plastic. I buy it from a local manufacture as scrap they cant use. This is great stuff for building machines, it cuts and machines very well.
In playing with building machines the last few years I found that wood on wood slides are not practical if you want accuracy and durability. Humidity can make it tight one day and loose days later. I have also used bushings on rods but I find that although they are smooth the clearance needed for them to slide can translate into looseness at the router bit.
So what I developed was, I used 6 roller bearings running in a grove under pressure, 3 on each side. This works very well. It is smooth and there is no play what so ever at the bit. It is driven by threaded rod with bevel gears I got from
The plunge is foot operated and is a separate mechanism than the router lift crank itself.

If you can view the video things are explained in more detail.

-- Mark, Newton, NC.

9 comments so far

View vetwoodworker's profile


101 posts in 1128 days

#1 posted 10-07-2014 03:39 PM

That’s awesome! Nice work!

View luv2learn's profile


2409 posts in 1724 days

#2 posted 10-07-2014 03:55 PM

This is a great build Mark, I like your unique innovations for the lift and plunge features. Do you have a positive locking feature after setting the bit height?

-- Lee - Northern idaho~"If the women don't find you handsome, at least they ought to find you handy"~ Red Green

View Mark55's profile


162 posts in 1485 days

#3 posted 10-07-2014 04:09 PM

I do not have a lock on the height adjustment. It was something I was contemplating and can be easily done. But being held up by threaded rod and pressure from the bevel gears it doesnt move. I tested it by letting it run for some time to see if vibration would move it and it didn’t. Time will tell on that if it becomes an issue I will lnstall one.

-- Mark, Newton, NC.

View exelectrician's profile


2327 posts in 1849 days

#4 posted 10-07-2014 08:36 PM

You are clearly moving router tables in the right direction. I can see Rockler knocking on your door wanting exclusive rights for you outstanding build.

-- Love thy neighbour as thyself

View jonsajerk's profile


34 posts in 1746 days

#5 posted 10-07-2014 11:02 PM

Man that is awesome!!!!

View Mark55's profile


162 posts in 1485 days

#6 posted 10-07-2014 11:34 PM

Thanks for the thumbs up from everyone. here is the video link if it makes it easier to see.

-- Mark, Newton, NC.

View Routerisstillmyname's profile


740 posts in 2930 days

#7 posted 10-08-2014 02:06 AM

1.25” thick wow. Awesome table.

-- Router è ancora il mio nome.

View Julian's profile


1010 posts in 2112 days

#8 posted 10-08-2014 02:50 PM

Great router table. Really like the clear top. Thanks for the info about the right angle gears. I have been looking for cheaper priced bevel gears for a project.

-- Julian

View Rick M.'s profile

Rick M.

7713 posts in 1801 days

#9 posted 10-09-2014 05:58 AM

Very cool. Are you the same guy who built a crosscut sled from thick acrylic?


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