R4511 Router Extension Part1

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Project by cFurnitureGuy posted 02-02-2010 07:25 PM 10463 views 47 times favorited 24 comments Add to Favorites Watch

This past weekend I finished up my router table extension on my R4511. this week i am working on an extensionfor the left side, So stay tuned!
any questions let me know!

i bought the Jessem Lift and router off of Craigslist last weekend and decided to save some shop space and build extensions on the my TS for a router table. So i stopped by the Metal SuperMarket and picked up a 6 ft 2×2 tube, 1.5×1.5 angle and ended up having to get a 2.5×2.5 aluminum angle for the front(1/4 inch thick). After a day of laying out holes and drilling and tapping new ones i got them all painted (machine gray) and started on the extension.
the extension is simply a MDF Top with a Formica Gray Laminate wrapped in a SYP trim. i think it turned out pretty well! the door on the TS cabinet clears no problem ! i still need to add a miter track and make or buy a router fence…. any tips or suggetions on building or buying router fence features is appreciated!!
this week i am going to try and built the left side extension as well so check back for that one!

-- Justin, Savannah,Ga

24 comments so far

View Jimmy's profile


44 posts in 3365 days

#1 posted 02-02-2010 07:29 PM

looks good cant wait to see the rest. am planning on doing that soon to my delta contractor.

-- 20 year old new woodworker. advice and tools much appreciated.

View Alonso's profile


949 posts in 3263 days

#2 posted 02-02-2010 07:35 PM

I really like it, any chance you can give us more pictures from underneath?

Nice work, I should do that.

-- The things I make may be for others, but how I make them is for me.

View Tim Dahn's profile

Tim Dahn

1567 posts in 3590 days

#3 posted 02-02-2010 07:41 PM

Nice! How is the router table attached to the saw? I assume it is bolted to the front and rear angles, is it also attached to the extension wing?

-- Good judgement comes from experience and experience comes from poor judgement.

View shopmania's profile


701 posts in 3207 days

#4 posted 02-02-2010 08:04 PM

I really like this! I have the R4511, and I love it except that the fence only goes out 30”. I’ve also been thinking about a new router table. What kind of fence did you upgrade to?? Do they all just slide on a 2” square tube and angle? Thanks for posting!

-- Tim, Myrtle Beach, Just one more tool, that's all I need! :)

View cFurnitureGuy's profile


145 posts in 3201 days

#5 posted 02-02-2010 08:31 PM

thanks for the comments! i can take more pics tonight and upload them. the table is bolted to the front and back angles with 3 bolts on each side. with the 1/4 inch thick angle on the front and the 1.5×1.5 angle on back (stock was 1×1) its pretty strong with no deflection. it is not attched to the TS extension wing at all… i didnt change the fence… i just added a couple of pieces of MDF with a gray woodgrain laminate. i may upgrade the fence later but it works well for now. when i purchased the router and lift it came on a table saw that had a jet xacta micro adjust fence and i thought about using it on my r4511 but the rails were like 56 inches on the right side and i didnt have the shop space for that… it would be nice to have the extra width but that doesnt work for me right now. but to answer your question the xacta fence had something like a 2×4 inch rail… you could make anything fit as long as the fence will fit the rails..

-- Justin, Savannah,Ga

View RexMcKinnon's profile


2593 posts in 3220 days

#6 posted 02-02-2010 09:34 PM

Nice router table. Are you supporting the weight with something other than the rails.

-- If all you have is a hammer, everything looks like a nail!

View cFurnitureGuy's profile


145 posts in 3201 days

#7 posted 02-02-2010 10:30 PM

as of right now i dont have any support for the rails… i put a straight edge on it and there is no deflection. but i have thought about adding some supports if needed!

-- Justin, Savannah,Ga

View a1Jim's profile


117115 posts in 3602 days

#8 posted 02-02-2010 10:31 PM

Good work Justin

-- wood crafting & woodworking classes

View SignWave's profile


440 posts in 3060 days

#9 posted 02-03-2010 12:53 AM

Looks good. I’m looking to do something similar with my 4511.

I’m curious, though, how thick is the 2×2 that you have? I have some in my shop, but I am afraid it’s too thin and won’t be stable.

I’ve seen other add the Starrett Measure Stix, another idea that I’ll probably copy.

-- Barry,

View Abbott's profile


2570 posts in 3328 days

#10 posted 02-03-2010 01:25 AM

That looks real nice. I would suggest a leg or two to the floor or a 45 degree support. Those fence rails will start to droop after awhile.

-- Ohh mann...pancakes and boobies...I'll bet that's what Heaven is like! ♣ ♣ ♣ ♣

View Skylark53's profile


2671 posts in 3085 days

#11 posted 02-03-2010 05:20 AM

Very nice and with your ingenuity, so much sweeter. Thanks for sharing.

-- Rick, Tennessee, John 3:16

View cFurnitureGuy's profile


145 posts in 3201 days

#12 posted 02-03-2010 05:23 PM

i have added some other pics of the underside… the one has the cabinet door on the TS open showing how it clears the router. SignWave, the square tubing i used is 3/16” thick. which is thicker than the stock tubing… i beefed up all the angles as well. thanks for all the great comments… i will have the other extension finished soon!

-- Justin, Savannah,Ga

View Dano43's profile


6 posts in 3163 days

#13 posted 02-03-2010 08:08 PM

I like it! I have the R4511 also. It’s a good saw, but heavy! I want to incorporate the combo into a full cabinet unit with built in dust collection. I was considering removing the right granite wing so the router table would have something sturdy to fasten to, but after seeing yours I think the fence rails (and a cabinet underneath in my case) would be enough support.

Keep posting pics of it!


View Bob Kollman's profile

Bob Kollman

1798 posts in 3216 days

#14 posted 02-04-2010 05:26 PM

nice work, nice router lift too!!!!

-- Bob Kenosha Wi.

View BIGRAY's profile


16 posts in 3131 days

#15 posted 02-07-2010 03:38 PM

That is a great idea when you have limited space in your workshop. You try to condense things. Good work, thanks for sharing.

-- Bigray's experiments

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