rebuilt router table top and fence

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Project by TerryH posted 01-13-2015 02:54 PM 1363 views 0 times favorited 2 comments Add to Favorites Watch

The baltic ply top on my router table had some significant water damage and I wanted to add some tracks for a fence. I had some 3/6” ABS scrap that I thought would provide a smooth, flat surface and a way to make my own T slots without spending a lot of money. I routed slots for the fence and a mitre and then cemented ABS strips into the slots leaving T slots that matched the bolt heads I was going to use for the hold downs. I made the nobs from PVC end caps and used a heat gun and C clamps to force the nuts into the caps. I needed to cut the tops off of a few of them for longer bolts. The top is cemented to the Ply and I also screwed it down. I think the screws are overkill. I’ll eventually fill the screw heads with ABS to make them less visible. I haven’t had any issues with material catching since they are counter sunk. once the top was glued down, I used the heat gun (after some trial and error) to fold the top over the sides.
The Fence is all 1/2” HDPE. Since HDPE doesn’t glue/weld easily, I used wood screws to hold it all together. I’m not crazy about the blue color but the local fabrication place that I get the scrap builds fuel and water tanks and always has blue in the scrap bin ($1/lb). The white is adjustable from the back and I can insert a sacrificial zero clearance from more scrap. I still need to make the dust collection plate on the back. I’ll probably use some clear plexi so I can see the bit from the back.
This is my first project- Looking forward to getting some feedback to make it better.

2 comments so far

View abie's profile


878 posts in 3974 days

#1 posted 01-13-2015 03:06 PM

Love it
wish I had access to that scrap around here.

-- Bruce. a mind is like a book it is only useful when open.

View TerryH's profile


4 posts in 1458 days

#2 posted 01-13-2015 03:37 PM

Plastic fabricators are everywhere. search for fabrication vice supplies. There are half dozen in San Diego. Most have a scrap bin. The bigger shops charge $2/lb but I found a smaller “mom and pop” that sells for $1. I’m sure your area has many more. I’ve found that woodworking and plastic share in tooling and processes. it does take practice to cut vice melt. ABS is easy to cut, route, heat shape (thermoform), and insanely easy to weld/glue.

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