How to Make a Router Table for Your Table Saw
Most large table saws have extension wings on each side of the table to extend the table. The wing to the right of the blade can often be removed and replaced by a home-built router table. The router can be removed when wide cuts on the table saw are required, and the table saw's fence can double as a fence for the router table.
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Things You'll Need
- Cabinet or hybrid table saw with removable extension wings
- 2 8-foot two-by-fours
- 3/4-inch sanded plywood
- Router
- Jigsaw
- Drill with drill bits, counterbore bit and screw bit
- 1 1/2-inch deck screws
- Tape measure
Instructions
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1
Remove the table saw extension wing furthest from the blade.
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2
Measure the dimensions of the removed extension.
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3
Build a four-sided frame of two-by-four boards (laid flat). The corner joints can be mitered, or for increased strength, joined using a half-lap joint.
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4
Cut and attach a piece of sanded plywood onto the face of the frame using 1 1/2-inch screws.
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5
Attach the frame to the table saw in place of the removed extension wing. Be sure that the plywood on top of the frame is flush and even with the saw's table.
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6
Position the router's baseplate over the center of the extension wing. Mark hole locations for the center hole and mounting screws.
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7
Drill the holes for the mounting screws and a 3-inch hole for the router in the center of the extension wing. Drill counterbores in the mounting screw holes.
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8
Install the router from underneath the extension wing using the counterbored holes for the mounting screws.
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1
Tips & Warnings
Be sure that your router bits have a long enough shank to accommodate the additional 3/4-inch thickness of the router table. You may wish to install a router lift or a router plate instead of mounting the router directly to the table if your bits are too short.
Whenever working with power tools, always wear appropriate safety equipment, including safety glasses.
