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Router Table
n The rooter is mounted to a remov- A The fence has a T-s!ot for attaching n A channel can be routed to accep t
able insert plate so it can be lifted ou t various accessories, and sliding faces your miter gauge . This is particularly
for changing bits or free-hand routing . allow for different sized router bits . handy for routing the ends of boards .
I(i SllopNotys No . 1
FEATURE PROJEC T
Open-Frame Base
EXPLODED VIE W `a HARDWOO D
DOWEL
te-.,
~ 21,.
"
14 x31/4 "
LAG BOLT
20 /2 "
LE G
PIECES
21 .,
36"
CUT
DADOES
TO FIT
RAIL S
NOTE :
RIP ALL 2x 4
/// STOCK, 3" WID E
CUTONGDETAIL
from two 2x4's cut to length an d three suet' hers (Note: To pro-
OPEN-FRAME BAS E then sandwiched together-, se e vide access to the router, there
This open-frame base is sturdy Exploded View . To provide mor- isn't a top stretcher between the
and easy to build . The entire bas e tises for the rails, I pm-cut wid e front legs. )
is built out of 2x-I 's. But before dadoes in each leg piece before glu - The stretchers are fastened to
started, I cleaned them up a littl e ing them together. (This simplified the frames with lag bolts . But
by ripping 1/4" off both edges, re- the joiro r'v . ) since the bolts are threaded into
ducing the width to 3" . see Gut- ASSEMBLY. After the dadoe s end grain, there's a trick t o
ting Detail above . are cut in the leg pieces, glue th e strengthening this ,joint.
END FRAMES . The base has legs and rails together to com- I drilled a hole near the end o f
two end frames that consist. al' plete the end frames, see Fig . 1 . the stretcher ari d. glued in dowel s
two legs and two rails. STRETCHERS . Next, the end before screwing in the lag bolts ,
THE LEGS . Each leg is made frames are joined together with see Fig. 2.
No . 1 ShopNotes 17
FEATURE PROJEC T
he heart of t .his router tabl e of the table to change hardwood, and covered with For -
T is the top . It has three im-
portant features, the removabl e
bit s, or to do freehand routing .
TECHNIQUE . The only tricky
mica on both sides .
THE CORE . The core of th e
insert plate, the miter gauge slot . part to adding an insert plate t o router table top is a sandwich o f
and its weight. the top is routing out. the recess . two layers of Masonite glued o n
REMOVABLE INSERT. The in- It has to fit exactly. (The tech top of a %1 " plywood base . Th e
sert plate is a piece of W -thic k nique we used is to rout th e idea here is to make a heavy to p
phenolic plastic (you could also recess with a pattern bit in a (to dampen vibration) . Also ,
use Masonite) that fits in a router, refer to pages 20 and 2] ..) when the recess (for the insert .
recessed opening in the ii .hle. plate) i .nci the miter gauge slo t
The idea is to screw the router TOP CONSTRUCTIO N are routed irr the surface of th e
to the bottom of the plate . The n The top consists of a core of ply cop, the two layers of Masonit e
you can simply lift the router out wood and Masonite, edged with provide smooth, hard edges .
18 ShopNotes No . 3
FEATURE PROJEC T
No. 1 ShopNotes 19
FEATURE PROJEC T
Insert Plate
After completing the top, the
next step is to make the rerov a
4 2" INSFRT . PLATE
IN "
- -
T DRILL t" DIA .
ble insert plate . T used a piece o f - FINGER HOLE S
plate 6 " from the front edge of th e saw to cut out the opening . so it aligns with the outline pre-
top so its centered side-to , sitle, T14E LIP. The next. step is t o viously drawn on the top .
and. trace around it, see Fig . . rout, the lip for the insert: plate t o Now place guide strips aroun d
Now the problem is to rout a sit on. The secret to getting the the insert plate, see Fig . 7 . Thes e
recess that has a lip around it t o outline of the lip to perfectly strips ik ill guide a pattern bit I n
hold up the plate. match the plate is to use the plate rout he lipped recess.
So, draw cut lines for the li p itself as a set-up guide for posi- The pattern hit 1 used has cut
in from the outline, see Fig . 6 . tioning the guide strips . ter length of 1". So, to provide a
Nov, drill a hole in each corner of GUIDE S'I'1UPS . To do this . surface for the hearing to rid e
Cultic strips
are r.r..srrl, t o
ft top
fr y /..
that's exactly
the .site q f the
insert plate .
40
20 ShopNotes No . 1
FEATURE PROJEC T
against, the guide strips need to depth to match the exact thick-
0 be 1' thick, see Fig. 7 . ness of the insert plate .
The strips should be 3" wide to To do this, mount the patter n
support the router. And two o f bit in the .router: Then place th e
the strips should long enough to insert plate on top of a guide strip ,
match the width of the top . see Fig. 8. Set the muter on top o f
(They're used later for routin g the insert plate and lower the bi t
the miter slot, refer to Fig . 10 .) until it barely touches the top .
After sticking the guide strip s Remove the insert plate and n Using a pattern bit in a router is a quick
down with double-sided carpet rout out the recess lip, see Fig . 9, way to rout the recessed tip to the top . Th e
tape, lift the insert plate out . To improve the air flow to the bearing on the pattern bit rides agains t
DEPTH OF CUT. Before routin g router, rout a chamfer on the bot- guide strips and cuts a recess exactly th e
the lip you need to set the bit tom of the opening, see Fig . Da . same size as the insert plate.
No . 1 ior-1Nutes 21
FEATURE PROJEC T
ShopNotes No . 1
FEATURE PROJEC T
No . I Shc lrNotes 2l
FEATURE PROJEC T
Top f3ar -~
The base of the fence is just a
platform for adding the Lop bar
(and tin- clamps) . The top bar ((';
f! _
S
saw by setting a dado blad e
:lightly less than the height of th e
base, see Fig . 7a. Then [ mad e
repeated passes to waste out th e
stock for the bit opening.
24 ShopNotr s No . 1.
FEATURE PROJEC T
Clamp System
0 The fence is almost complete, al l
that's leFt . is (lie clamp system .
CLAMP SYSTEM . What make s
this claxnp sysl .ern work is a Car -
riage bolt that passes through th e
clamp head and up through th e
fence . By tightening a knob (or
wing nut) on the bolt, the clam p
head pinches against the botto m
of the table top, holding the fenc e
in place, see Fig. tin.
THE CLAMP HEM) . Each
clamp head consist~ of tw o
pieces - a spacer' that's slightl y
thinner than the top, and an (ter n
that extends under the table top .
The clamp heads are "hinged "
to the fence with Masonit e the same width as the route r side-to-side on the table top .
splines, see Fig . 8 . The and . re- fence base (A) (13/ 4 "), see Fig. 9 . Then measure the amount of
quirement is to cut matchin g SPACERS. Next, determine th e overhang on each side (3") and
kerfs in the spacer and the fence . thickness of the spacers (E) by subtract r/t;" for clearance (2 74;") .
To cut these kerfs safely, I measuring the thickness of you r Now cut two spacers (E) t .n
glued the spacers to a long arm router' table top . Then, for clear-- these dimensions. and glue them
blank first . (Later. I cut the arm arice, sv!.lhtcact IA " . (This creates a to the arm blank (I]), see Fig . 9.
blank in half to make two clam p space so the assn L'an pinch agains t SPLINE HINGES . The next step
heads, see Fig. 9.) the table top, see Fig . pia.) is to cut kerfS for the 3/,. " Masonit e
ARM BANK . To make the arm To determine the length of th e splines, see Fig. 9.
blank (U), cut an 8"-long blank to spacers, center the fence from To align t he pieces, use the ri p
fence on the table saw to positio n
9 kerfs in the bottom of the fence ,
and then, without changing th e
set-up, cut kerfs in the spacers .
Now. cut Masonite splines 1/s '
wider than the combined (lei }I h of
the kerfs (r/4 ") . And finally, befor e
cutting the blank in half. I cu t
bevels on the ends (for . appear-
anee), see Fig. 9 .
CARRIAGE BOLTS . These
REVEL EN D
clamp heads are attached to th e
fence with carriage bolts .
The easiest way to get the hole s
0 to align in these two pieces is to
Fasten the clamp heads to the
fence with carpet tape, and drill
through both pieces, see Fig . 10 .
ShopTip : If your drill bit isn' t
long enough, drill as fax as yo u
can. remove the clamp heads an d
complete the hole . see Fig. I10a .
fLNIISH . Before assemblin g
the fence, I applied two coats o f
tung oil finish to keep the woo d
parts from getting soiled .
No . 1 ShopNotes 23
FEATURE PROJEC T
Fence Accessories
Router Ott Guard
n For safety . you should includ e To make the guard. first cut th e
a bit guard on the router table . back to size, and cut two z" slot s
This one is designed to attach t o for adjusting the height .
the fence with T-nuts an d The shield is cut from 1/= " - thick
threaded knobs . Plexiglas . and screwed to the
The guard is made of tw o back . This whole assenthly i s
pieces : a l " -thick hardwood hac k simply attached to the fence wit h
piece, and a Plexiglas shield. threaded knobs, see Fig. 2.
T-SLOT - -
Hu T
r} RAP]U 5
NA . --"a-k.,D
HOLE
HEIGI I T
AO,JUSTMEN T
SLOT
r KA2]iU5
" /`
COuNrErSIN S
!%+i ' -THICK
PLEMOL A s SHANK HOLE
SHIL I C
2
hrt _ . 10" .-
I~ 23a "
SLOTS FOR
MOUNTING 1 r
/2 '
SCREWS- ~ ._ 1 ,,z,r- -^ . -
2"
-- . . . --- -~ : -- /S '
- NOTCH FO R
45 - SLIDING FACES O F
F.OIJTEKTASLE FENC E
26 ShopNoteS No . 1
FEATURE PROJEC T
Feathethoard
gees, attach a tall auxiliary fence 9 t2"-THICK STOC K
to your miter gauge, see Fig, 2 .
Now, tilt the table saw blade to
:Wand raise it to make a I t/A "
high out, see Fig . 2a .
Once the blade height is set ,
make 17 equally spaced cuts . ('Phi s
leaves 18 fingers . )
CUT THE SLOTS. The last ste p
n A featherhoard is helpful for is to make two slots for attachin g
keeping boards tight against th e the featherboard to the fence . To
table for a consistent cut . make the slots, drill 34 " holes ,
To make this one, cut a work - 2 2/4 " up from the bottom edge o f
piece from 1/2-thick stock with the featherboard . Then, cut out
both ends cut at 3tY, see Fig . I . the slots with a sabre saw or ha rrcl
THE FINGERS . To cut the fin - saw, see Fig . 3 .
2 3
Vacuum Attachment
to your shop-vac, see photo . hose will fit snug. see Fig_ 2 . f flu e
To build the attachment, cut tw o the pieces together and the n
triangular-shalaet l .~ fif e p re 'ex from Screw the at .tarhmnen [ . to the bac k
112 ' -thick stock . see Fig . 1 . of the fence .
TOP PLATE . Next, make a fac e PROBLEM. As you're driving i n
Mate from 1/t " Masonite . It's 5 " the screws, the bottom q f th e
wide and beveled on the top an d vacuum attachment is force d
bottom edges to match the side down and tends to lift the fence .
pieces, see Fig . 2 . (This allows the To get around this, put . pennie s
n Here 's an easy-to-build dust attachment to fit tight agains t under the sick, pieces befor e
collection s\stem that screws to the fence and the table . ) starting the screws, After they'r e
the hack of the fence (over the HOLE SIZE . Nov, drill a hole i n St. e t ed. remove the pennies an d
router bit opening) and connects the face plate so your vacuu m finish tightening the screws .
No . 1 ShopNczl :es