Router Table Adventure

I have just completed a router table build ... not for the first time, I must add, and probably not for the last time. This one is a little more than the last, and I’m sure that the next might be a little more than this one.

The irony is that I do not use a router table very often … possibly only a few times each year! So why have I gone to all this effort? Well, because it is fun and interesting.

This is as full-on a set up I could build. What is relevant is that the essential parts did not cost that much (links to parts included), relative to what is available from the big names. The essential parts are the router (an Elu 177e, purchased used on eBay UK for about $100), the aluminium insert plate, was purchased about 3 years ago from Timbecon ($100), a Router Raizer lift ($100, available from Rockler), and a MuscleChuck ($100), a router bit extension for above-table bit changing. All up, with the fence, about $500. I would argue that this compares well with set ups in the range of $2000 and upward.

There non-essential (but fun and useful) items, such as the JessEm ClearCut Stock Guides ($79 on special from Woodcraft), and the Wixey Digital Height Gauge ($105, eBay).

The base for the router table was a laminated high pressure MDF kitchen bench off cut from a kitchen maker ...

Screws are used for levelling …

… track installed for the fence …

… and a scale glued to the track for fine adjustments …

This was built into the outfeed of my Hammer K3 sliding table saw ...

For those with the K3, this is how it was attached (photos of the previous router top) ….

The top ...

... is secured at one side by bolts into inserts (there are convenient holes in the saw case) ...

Facing the saw, add bolts as levelling legs ...

And the far side I used existing bolt holes to support an aluminium section ...

Replaced the bracket for the table extension …

All bolted down (current router table) …

The on-off switch has seen a few router tables. I prefer it at my right hand. The router connects to this, and then the switch connects to the vacuum cleaner, which has automatic on-off when the switch is thrown.

These Timbecon aluminium plates are excellent. After 3 years of hanging the heavy Elu 177e (predecessor of the DeWalt DW625) , there are no signs of any dipping. The surface remains flat.

The stripped Elu below, minus handles, with Router Raizer attached ...

Above the plate, the MuscleChuck allows for changing bits and easy bit-holding. I built a handle for the Router Raizer from a cut-down socket wrench. This enable fast spinning as well as fine adjustments with the fence close by.

The advert for the Router Raizer reveals the parts and how it is connected …

The heart of the fence is made for 8020 extruded aluminium (80mm high and 20mm wide). I comes in 1m lengths ($28, eBay), and this fence is 600mm long.

Note that the slots of this extrusion use different T-track bits (common T-track bit at top) ...

The only other parts I bought in were the sub-fences ($31 from Timbecon), since these are phenolic-coated (UHMW polyethylene), which is hard-wearing and slick, and the dust port (also Timbecon).

Also note that the dust collection port in the main fence was made with a 2 1/4" hole saw ...

The JessEm guides, and the guard I made ...

The JessEm guide does two things simultaneously:

1. Rollers are fitted with one way roller bearings to ensure each roller spins in the direction of the feed to prevent kickback.

2. The wheel is angled inward 5 degrees, towards the fence, which locks the work piece against the fence for a clean cut ....

The guard is made of acrylic, formed in two sections and superglued together ...

The rear of the fence, with the dust port, and sub-fence adjusters ...

The reason for bolting on the dust port was not simply to make it possible to attach, but this enabled the T-track to be plugged and maximise dust extraction ...

I originally built UHMW square brackets for the fence, then replaced them with a set from Banggood, which were stiffer (knobs again from Timbercon) ...

The fence is square to the table ...

I have considered adding a micro-adjuster. Frankly, the tap-tap of a mallet or hand works just as well.

Here is the basic extrusion. A spacer is added to extend the track a couple of millimetres past the sub-fences ...

The spacer is UHMW (I wanted something I could machine to size, and liked that it was black and will not degrade), which is hard and fairly stiff. However, there was a smidge of flex, and so added a lot of T-bolts. I should point out that this is only made necessary as the JessEm hold downs are used. They have wheels which need to not be allowed to flex away ...

The last photo is self-explanatory ...

For dust extraction, I was inspired by the MilesCraft system …

I did purchase one, and discovered that it did not fit the Elu router well enough. I passed it on to a fellow woodworker, and decided to make something similar.

The dust collection consists of below table collection from the router bit ...

Note: the Elu 177e is a 30-year old router design, and they did not come with dust control in those days! Elu was taken over and became DeWalt. The DeWalt DW625 is the same router .. and this comes with a dust spout. The base of the DeWalt is not quite the same design, but close enough to modify to fit. Which I did.