Router Insert Plate- Need advice on making my own

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Forum topic by monster1971 posted 10-19-2015 06:30 PM 651 views 0 times favorited 5 replies Add to Favorites Watch
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45 posts in 994 days

10-19-2015 06:30 PM

Topic tags/keywords: router insert aluminum insert polycarbonate insert

In the process of converting a workbench into a router table. Have gotten a lot if useful information off of LJ but the one thing I need help w/ is advice on making my own Insert Plate or just biting the bullet and buying. I can get either a blank Aluminum or Polycarbonate 1/4 or 3/8 sheet from the internet for about $25. The one thing that’s an advantage of just buying a pre-made one is the inserts that you can swap out.

I can get the Kreg w/ 3 inserts for $50 from Amazon or a Bench dog for a little more ( 1 insert). I thought by doing it myself I could save some cash but just checking to see if its really worth it.

Anyone made their own or advice on this?

How about inserts?

Aluminum Blank

5 replies so far

View Kaleb the Swede's profile

Kaleb the Swede

1833 posts in 1967 days

#1 posted 10-19-2015 06:33 PM

I am making one of my own right now out of 1/2 inch cutting board I got from a restaurant supply place. I did it so I can have a couple of different sizes all for thirty bucks.

If you get a big enough sheet of the stuff you are using you have material for multiples. I say go for it

-- Just trying to build something beautiful

View monster1971's profile


45 posts in 994 days

#2 posted 10-19-2015 07:36 PM

Kaleb, like this cutting board?

View HokieKen's profile (online now)


4996 posts in 1136 days

#3 posted 10-19-2015 08:28 PM

I made 2 inserts myself. The first from MDF w/ formica, the second from 1/2” HDPE. Both sagged under the weight of my 3.25HP PC router within a few days. I bought the Kreg plate and after several months, it’s still flat with no sag. If I were doing it all over again, I’d save myself the time and headache and buy one right out of the gate. I’m usually a build-it-myself guy, but in this case, the 20-30 $ it saves just isn’t worth it. Especially with the twist-loc inserts that Kreg has.

That being said, 3/8” aluminum is a solid material choice. PC maybe fine too depending on the router you’re hanging on it.

For inserts, I cut some 3” disks from 3/16 Lexan and cut a rabbet for them in the HDPE plate I made. I seemed to work fine with a little carpet tape to keep them from blowing up. If you do make some, I’d suggest incorporating some kind of hold down method.

Again though, for my $.02, the Kreg plate is a fantastic product and worth every penny.

-- Kenny, SW VA, Go Hokies!!!

View bigblockyeti's profile


5120 posts in 1718 days

#4 posted 10-19-2015 09:48 PM

I made mine from 1/2” lexan. It’s held up well supporting a 1 3/4hp router and a 3 1/2hp router.

View pintodeluxe's profile


5658 posts in 2811 days

#5 posted 10-19-2015 11:16 PM

You might check Bench Dog, they have some really nice aluminum plates. They won’t sag, even with a 13-15 amp router.

-- Willie, Washington "If You Choose Not To Decide, You Still Have Made a Choice" - Rush

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