Workshop Improvements #1: Router table in table saw extension

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Blog entry by wasmithee posted 01-17-2011 05:51 PM 3361 reads 7 times favorited 11 comments Add to Favorites Watch
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11 comments so far

View jw3's profile


3 posts in 1817 days

#1 posted 01-17-2011 07:03 PM

Love it….. would like to build one….. anyway you would share the specs..?

View b2rtch's profile


4371 posts in 1832 days

#2 posted 01-17-2011 07:03 PM

Looks very good.
Mine does not look this good.

-- Bert

View lew's profile


10204 posts in 2539 days

#3 posted 01-18-2011 03:24 AM

Nice! Really like the dust collection setup!

-- Lew- Time traveler. Purveyor of the Universe's finest custom rolling pins.

View wasmithee's profile


55 posts in 1477 days

#4 posted 01-18-2011 03:54 AM


I plan to post more detail about this once I am finished with it. I’m not entirely happy with the phenolic plywood as it is not perfectly flat. It makes the fence not an ideal solution since it isn’t consistent around the bit opening. I am planning on replacing the face pieces with laminated MDF. The table itself isn’t perfectly flat either, however since it is screwed to a flat frame the variances aren’t noticeable without a feeler gauge, so I am calling it good enough.

I also pan on adding a miter track/t slot to the table. I read several blogs where this was debated one way and the other. In the end I have been using it without the track(s) and have found I’d really like to have them to position feather boards in particular and sleds secondarily as most sleds could be made to ride the fence anyway.

The table is an adaptation of the one that appeared in Fine WoodWorking Tools & Shops 2010/11 No.216 “Space-Saving Router Table” pg 50.

The segmented fence is based on the one described in Wood magazine Best-Ever Router Tips, Tricks and Jigs 2008 chapter 4 “Do-it-All Router-Table Fence” pg 94. Here’s are the plans from an earlier publication:

View wasmithee's profile


55 posts in 1477 days

#5 posted 01-18-2011 03:58 AM


The dust collection as described in the FW article is ingenious. I used a couple of fittings I could only find in a kit I bought at WoodCraft. I did not use most of the components in the kit, but a couple of the fittings worked perfectly. The kit is called: “Router Table Dust Collection Accessory

View bigike's profile


4035 posts in 2072 days

#6 posted 01-18-2011 05:06 AM

nice set up.

-- Ike, Big Daddies Woodshop,

View need2boat's profile


544 posts in 1476 days

#7 posted 02-17-2011 08:26 PM

Why did you change up fence designs from FW design? I’m considering add one to my powermatic and look for ideas. I’ve not worked with phenolic plywood. Is that a coated cabinet ply?



-- Second Chance Saw Works Blog: Positive Rake

View wasmithee's profile


55 posts in 1477 days

#8 posted 02-17-2011 08:35 PM

I liked the Wood magazine fence design better. I had to blend the two a bit to accommodate the under the table dust extraction. No big deal really, just omit the hole in the fence for the dust hose and instead cut out the bottom of the fence behind the bit so that the dust can go down the hole in the router table top. The adjustable segmented fence is great. It is also taller than the FW fence which is a big plus when running longer boards on end etc.

Phenolic plywood is coated Baltic birch plywood. It was originally created for use as a concrete form, but has found its way into jigs for the wood shop due to its slickness. As I mentioned in an earlier response to this blog entry, I would not use it again for this project due to it not being perfectly flat as I had assumed it would be. I think it would be used for a lot of other jigs and fixtures, but not where you need to make a perfectly flat top or fence.

If I were to do it again I would apply a laminate to a MDF core… I still may for the fence. I’m not sure the top is bad enough to justify the effort of rebuilding the top. I have other projects I’d rather work on at this point.

View need2boat's profile


544 posts in 1476 days

#9 posted 02-18-2011 12:29 AM

I’m going to do a bit of torrent searching on the web tonight and I’m sure I can find the wood magazine PDF. I’ve found most issues of all the magazines.

I was planing to use cabinet grade birch for the top since I’ve yet to work with formica laminate which I’m guessing that’s what most aftermarket places would use..

How do you like Triton 3 1/4HP Router? I’ve been reading a bit and it seems like it has one of the better dust collections out there for a table router. It looks like you made your own plate as well?

thanks for sharing


-- Second Chance Saw Works Blog: Positive Rake

View wasmithee's profile


55 posts in 1477 days

#10 posted 02-18-2011 12:54 AM

I really like the Triton router. Mine is a 2.25 hp model, but I haven’t needed anything more. I’ve thought about upgrading it since I need a plunge router anyway, but for now it is working flawlessly in the table.

Dust collection is great. The built-in shroud on the Triton works great and my 2HP dust collector sucks everything up well through both the fence and table.

I made my own router plate using a piece of ballistic acrylic my dad gave me. I made it the same size of a commercial plate so that I can change it out when I get the chance. It is nice that it is clear, but I would like to have something more rigid, with leveling screws and interchangeable inserts to adjust the size of the bit hole. If someone made a clear one with these features that would be great, but I have not see such a plate.

Here is a link to the instructions for making the fence:

View john1102's profile


60 posts in 1452 days

#11 posted 02-25-2011 07:27 PM

nice photos and work.

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