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Homemade Router table extension wing question

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Forum topic by Nick posted 04-05-2013 08:11 AM 1738 views 0 times favorited 17 replies Add to Favorites Watch
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Nick

35 posts in 798 days


04-05-2013 08:11 AM

So i just ordered a router plate from rockler. my plan is to mount it on the left wing of my table saw. i plan on using a high end CNC mill to cut out the hole for the plate in my cast iron. the question i have is after i leave the ledge will it still be thick/strong enough. i will have roughly 1/8” thick of iron left for support the plate plus router. also do u think it would compromise the strength of the overall wing?

additional info:
router plate dimensions 8-1/4” x 11-3/4” x .25”
table saw extension wing 27” x 12” x ~.36”
router being used Bosh 1617

-Nick
EDIT:
finished product is here
http://lumberjocks.com/projects/83077


17 replies so far

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bluekingfisher

1055 posts in 1667 days


#1 posted 04-05-2013 08:25 AM

Brave move Nick although I should think the remaining material should be enough to support the base plate and router. Remember, the weight of the unit will be spread across the area of the lip over its entire surface, it could probably take your weight. There are store available wings with the exact same set up available so if its safe for them should be OK for you.

Good luck.

David

-- No one plans to fail, they just, just fail to plan

View Mark Davisson's profile (online now)

Mark Davisson

501 posts in 2005 days


#2 posted 04-05-2013 10:48 AM

Nick, I think your plan is a good one.

-- I'm selfless because it feels so good!

View MrRon's profile

MrRon

2860 posts in 1931 days


#3 posted 04-05-2013 07:39 PM

A router plate is around 1/4” to 3/8” thick. I doubt that the CI wing on your saw is that thick. It may not even be thick enough to maintain a flush surface. I base this on my own saw which is a Jet cabinet saw. How do you plan to cut the hole? CI is not easily cut using hand held tools. You are talking a major metal removal job suitable only for a rigid machine set-up. Typically the way to cut a round hole in a cast iron plate would be to mount it on a vertical milling machine and using a boring head remove metal in progressively larger diameters and depth.

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Nick

35 posts in 798 days


#4 posted 04-05-2013 10:09 PM

i plan on using this mill to cut the hole. it is plenty powerful and im going to run a program that cuts it exactly to the specs of the router plate using its CNC function. i measured my cast iron thickness and got around 3/8” the plate is 1/4 therefore leaving around an 1/8”

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MrRon

2860 posts in 1931 days


#5 posted 04-06-2013 04:28 PM

With that mill, you shouldn’t have any problem cutting the hole. I guess you will be using a straight end mill and using the CNC to trace the round shape. No need for a boring head. That should get you a nice CI slug left over for another project. Thanks for the update.

View jenniferzinger's profile

jenniferzinger

5 posts in 564 days


#6 posted 04-06-2013 05:15 PM

Nick, I think your plan is a good one.

View MrRon's profile

MrRon

2860 posts in 1931 days


#7 posted 04-07-2013 06:57 PM

Sorry; I didn’t read your thread fully before replying. I was thinking a round hole until I re-read the message as it being a rectangular cutout. Your plan is absolutely right-on. Blame it on old age.

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Nick

35 posts in 798 days


#8 posted 04-08-2013 01:24 AM

The link to finished product will be up soon

View oldnovice's profile

oldnovice

3790 posts in 2055 days


#9 posted 04-08-2013 06:00 AM

Why not just buy the Benchdog router table TS extension wing as it has been tested to not only hang on your TS but also support your router, inserts, and router lifts?

I have had one for 5 years and I am thinking of adding another!

-- "I never met a board I didn't like!"

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Nick

35 posts in 798 days


#10 posted 04-08-2013 06:06 AM

The reason I didn’t is b/c they cost $450. That is where I got the idea though. My school wood shop has one on both their table saws and really liked them

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Nick

35 posts in 798 days


#11 posted 04-19-2013 11:56 PM

here is the finished product
http://lumberjocks.com/projects/83077

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oldnovice

3790 posts in 2055 days


#12 posted 04-20-2013 05:23 AM

I posted a comment on your finished project page and as I said, ”can’t get better than that”!

-- "I never met a board I didn't like!"

View Lee Barker's profile

Lee Barker

2169 posts in 1538 days


#13 posted 04-20-2013 01:43 PM

Nice work. I’m too late to respond to the OP’s questions, but perhaps it would be of value to others: why the plate?

Wouldn’t it make more sense just to machine a hole and machine the backside flat and bore and countersink for the screws to hold the bottom of your router in the cast iron itself?

I could easily be wrong, but I can’t see a reason to inset the plate in a cast iron wing.

Kindly,

Lee

-- "...in his brain, which is as dry as the remainder biscuit after a voyage, he hath strange places cramm'd with observation, the which he vents in mangled forms." --Shakespeare, "As You Like It"

View Nick's profile

Nick

35 posts in 798 days


#14 posted 04-20-2013 01:55 PM

I have gotten that question a few times and I have a few reasons for the plate. My biggest reason is because I don’t have a router lift so a bit change would be very difficult once I get the cabinet made around the thing. Another reason is someday I may get a different router and if I have the holes drilled specifically for that router well then I would have 3 holes in my cast iron. lastly that hole is the industry standard router plate size so any plate can drop in therefore making it a lot easier to buy/make a router lift in the future

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oldnovice

3790 posts in 2055 days


#15 posted 04-20-2013 02:29 PM

I don’t know if I have said this before but I swap out routers with different bits and set up height for a project as it is quicker and found out, at least for me, to be more accurate. But, in he other hand, tat could also be done w/o a plate.

A router lift would be nice! Like this one
which has been on my which list for some time!

Just one suggestion, put the leveling adjustments on the plate so you can level the plates from te top of the RT!

-- "I never met a board I didn't like!"

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