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Table Saw Router Upgrade

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Project by AaronS posted 135 days ago 1485 views 4 times favorited 12 comments Add to Favorites Watch

A couple of weeks ago I built a router table that fit into the extendable table on my Porter Cable 220TS table saw. I wasn’t happy with it so I tore it down, except for the fence, and rebuilt it correctly. I used 3/4” melamine. I had to route out a small portion (about 1/4” deep) on the under side for the mounting screws to work and to make sure I could fully raise the bits high enough. I also had to route the sides down about 3/8” to make the top flush with the table saw. This works good though because it keeps the table secured nicely.
I am very happy with how it turned out. This is the first time I have used the t-track and Kreg featherboards on any of my projects and I am very satisfied with how they work. My only regret is that I didn’t do this sooner!





12 comments so far

View MW_Woodworking's profile

MW_Woodworking

20 posts in 291 days


#1 posted 135 days ago

Great idea! I have that saw but never thought of putting a router insert in the expanding wing. I will definitely try this.

-- Matt ~ "Show us a man who never makes a mistake and we will show a man who never makes anything.” - Herman Lincoln Wayland (1830-1898), author

View steve_in_ohio's profile

steve_in_ohio

1017 posts in 212 days


#2 posted 135 days ago

wow, great work, that is a very nice router table

-- steve, simple and effective woodworking---

View NormG's profile

NormG

3998 posts in 1605 days


#3 posted 135 days ago

Wonder addition to the side of the saw, great idea to incorporate what was already available

-- Norman

View cbfodalo's profile

cbfodalo

20 posts in 148 days


#4 posted 135 days ago

I have same saw, I use it as portable jobsite saw. I did similar setup, I did not build fence, rather I attached a piece of poplar to table saw fence. This way I can use Ts fence for both router and Ts. No need to break down fence for rips, just lower router down, and I have 24” rip capacity. I also built a 38”x53” table that saw with router drops into, this sits on a set of adjustable horses, I used leftover poplar for frame, and azek for top, rounded all edges. I now have about 12” outfeed. It is light and easy to breakdown and setup, I will post pictures once I get a minute.

-- Healthy Homes, NJ LLC

View AaronS's profile

AaronS

19 posts in 211 days


#5 posted 134 days ago

CB- I thought about using the existing table saw fence, but I couldn’t slide it all the way over because the router table sits on the fence rails. How did you get around this? Let me know when you post the pictures. I am interested in seeing it.

View Lumberpunk's profile

Lumberpunk

186 posts in 938 days


#6 posted 134 days ago

Hey this is a great idea and would work on my Bosch 4100 but I am wondering if the weight of the router distorts the rails at all… over time? would be interested to hear your thoughts on this.

View AaronS's profile

AaronS

19 posts in 211 days


#7 posted 134 days ago

I don’t know if it will distort the rails, but I am taking precautions like it will. For now I take it out when not use. In the future I am going to build a cabinet around the saw which will support the rails.

View a1Jim's profile

a1Jim

112000 posts in 2178 days


#8 posted 134 days ago

Nice set up,good thinking.

-- http://artisticwoodstudio.com Custom furniture

View cbfodalo's profile

cbfodalo

20 posts in 148 days


#9 posted 133 days ago

AaronS, I routed out about a 16th off the back of a piece of cabinet grade 1/2” plywood, and pinned a small 1/2” x 1” brace along front and back of insert. My router inserts hangs over rails, just about 5/16” on the front and back, this allows the fence to work all the way to the end. I checked today, I get about 26” rip. I also installed a 2” washer with thumbscrews under the front and back rail to hold it down. The braces run parallel to the rails, so they keep the router insert tight, I eased all the edges, and made it a very snug fit, it works great. your fence is much nicer then what I use, but I use this as jobsite setup, so I really need something easy to breakdown and do mostly dado, and round over cuts, so I really do not need anything crazy. I have another router table setup I also use on larger projects, a Bosch Ra1200, but most of the time, I just use the PC table saw / router table combo. the shop vac hood attached to the top works pretty well too. I braced under the rails with strips of the same 1/2” plywood to support them while they support the router table. I am not all that concerned with this $300 saw, but it does work pretty well. I do quite a bit of interior and exterior trim, and the saw and router combo has served me very well.

-- Healthy Homes, NJ LLC

View AaronS's profile

AaronS

19 posts in 211 days


#10 posted 133 days ago

CB-On my first attempt at this project I used 3/8” plywood and did the same thing you did – made braces underneath that fit against the rails. Since I routed rabbets in each side of this one, I didn’t need the braces. I thought about making the table short enough to still be able to use the fence, but it’s not hard to take the router table out if needed.
I like the saw ok. I don’t think you can beat it for the price. This is the 1st table saw I ever purchased and it has served me well. Now that I have been doing woodworking for a few years, I have learned that it does have its limitations. The miter slots aren’t exactly true and the fence system leaves a lot to be desired, but overall it serves me well.

View cbfodalo's profile

cbfodalo

20 posts in 148 days


#11 posted 132 days ago

aaron, sounds like we had same idea… here are the pics I took in this morning. I have some melamine that I think I will build the insert for the third time… I will stay with this config, it is simple and works well. I used to use the table saw with router insert on the factory rolling stand, but I found the stand to damn flimsy for a jobsite. it wobbled, and just could not hold up to the work. the new setup is a little hard to set up, but give me a nice height, more stable and a bigger table with outfeed. the adjustable horses are pretty handy too, I can set height to match my miter saw stand and my big work table.

-- Healthy Homes, NJ LLC

View AaronS's profile

AaronS

19 posts in 211 days


#12 posted 131 days ago

CB-That looks good. I agree – the rolling base is too flimsy. My next big project will be to build a rolling cabinet for the saw. I definitely suggest using the melamine, I am glad I did.

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