Adding A Router Extention To Your Tablesaw
Adding a router-table extension to your
contractor-style tablesaw is fairly easy to
accomplish—simply remove the metal extension that’s
there now, and then build and bolt this one into
place.
Important note: This table was built for a
specific 10" saw model, so the dimensions and
connections may vary somewhat for your saw.
As a general rule, you should plan to make the
tabletop as wide as the extension being replaced and
as long as the front and rear rails can sturdily
support. Sometimes, the extension table can be
slightly longer than the metal extension it
replaces.
Constructing the tabletop assembly
1 Cut the extension table- top (A) to size
from 3/4" plywood.
2 Cut the banding strips (B, C) to size,
mitering the ends as shown in the drawing on the
next page.
3 To mount the banding strips to the plywood,
drill and countersink mounting holes through the
strips and into the tabletop edges. Making sure the
top edges are flush, glue and screw the strips to
the tabletop. Sand the top surface of the banding
flush with the top of the plywood tabletop.
4 Measure the length and width of the banded
top, and cut a piece of plastic laminate to the
measured size plus 1" in length and width. Using
contact cement, center and adhere the plastic-
laminate to the top of the tabletop assembly (A, B,
C).
5 Fit your router with a flush-trimming bit,
and rout the edges of the laminate flush with the
edges of the banding.
6 Follow Steps 1 through 5 on the Tabletop
Layout drawing to form the opening in
the tabletop for the router plate. (Tip: when
routing the 3/8" rabbet 3/8" deep in Step 5, it’s a
good idea to go 5/16" deep on the first pass, and
then 1/64" deeper per pass until the top surface of
the plate is perfectly flush with the top surface of
the table-top laminate. (Your other option is to
have a piece 3/8” acrylic cut to size.)
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Mounting the extension to the saw
table
1 Follow the four-step
drawing below to mark the mounting
holes in the tablesaw extension.
Before drilling, double-check that
the top surface of the extension
table will be perfectly flush with
the top sur face of your saw table.
2 Use a chisel to form
notches (1-1/2" wide by 1-3/4" long
by 1/2" deep) on the bottom side of
the extension for housing the
hexhead bolts. Fasten the extension to
the saw table.
3 Using the holes in the
guide rails as guides, mark their
location onto the outside surfaces
of both banding pieces (C). Remove
the extension table from the saw
table and drill the guide- rail
mounting holes where marked. See the
End View for reference. Chisel a
notch (3/8" deep) on the inside face
of the banding strips (the mounting
bolts aren’t long enough to go
completely through the ¾" thick
banding).
4 With the top edges
perfectly flush, fasten the
extension table to the saw table and
rails.
STEP 1 Mark and transfer the
centerlines from the saw-table holes
to masking tape.
STEP 2 Position the extension
table against the saw table, and
transfer the marks.
STEP 3 With a square, extend
the lines down the edge of the table
extension banding (B).
STEP 4 Measure the distance
from the top of the saw table to the
centerline of the existing hole.
Transfer that dimension to the table
extension. Drill the mounting holes
through the banding. |
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