Building a new router table/bench

[98TJ]

Had a guy ask me to make some house vents for him and while making them I decided I needed a new router table. The table I've been using is a simple thing made from MDF that we used at the car audio shop. It was a basic thing. No dust collection built in, no miter track or anything, just a MDF frame with a pocket for a JessEm router lift and an Alucobond top surface. Great for templates but not much else.

It was fine at the shop because it was in a dedicated wood shop and dust wasn't a big concern. BUT...at home it makes a big fawkin' mess.

I researched different router table ideas/plans and didn't see anything that made sense to me. Seems like everyone builds a router table for nothing but routing. Whether it's a freestanding table or an extension on a table saw, the only purpose they serve is for routing. I wanted something that would allow me to have the ability to rout anything I'd want, but when it wasn't being used as a router would still serve a purpose.

Went to Woodcraft to get some Incra miter and T-Tracks. Wanted to go ahead and get the router fence but they didn't have it. While there I saw they had a sale on 1 1/2" x 27" x 60" birch workbench tops. Grabbed one of those as well.

A few pics.

A buddy came over yesterday and, while BSing, I cut a slot for the miter track and the pocket for the router lift.
https://sphotos-a-sjc.**.fbcdn.net/hphotos-ash4/1002353_3392724474177_1153106901_n.jpg

Rubbed some Minwax Natural stain on it.

Then I realized I put the miter slot where the T-Track was supposed to go. Shouldn't have been BSing so much, I guess.

Cut a new slot for the miter track (in the proper location this time) and widened and extended the slot for the T-Track. With the new top laying on the old router table the work height is 38 3/4" which is good for me. Raised the Gladiator bench with maple top to the same height.
https://sphotos-b-sjc.**.fbcdn.net/hphotos-prn1/532504_3395407861260_1832856300_n.jpg

Picked up a couple of sheets of 3/4" maple plywood today - couldn't get birch, but that's OK. I figure the base cabinet will be 56" wide and 24-25" deep. Plan on four 2 1/2" swivel casters. The two front casters will have dual locking brakes.

The base/cabinet will have storage for all the router bits and jigs, self-contained vac system, and who knows what else. I have the general idea for the base and what I want, but need to sketch it out and nail down dimensions for all the pieces.

 

[Thumper68]

Looking very good. I made my own fence as well, I will take some pics of mine this weekend. All the taller commercial fences that I liked were way to $$$ for what you get.

If you do buy one I would suggest making sure that there is a provision for dust collection in the fence, I have a port in the fence and one in the cabinet.

 

[98TJ]

I've decided to get the Kreg precision router fence. I like that over all the others fences I've played with and seen made.

 

[1/2 Cup]

Looking great, keep up the good work and the pics coming!!!

 

[98TJ]

Spent some time getting the basic framework drawn up and had a buddy come over to have me do some electrical work for him. Did that and got him to hold a sheet of plywood while I cut the back out with a 18V DeWalt. Used a piece of 3/16" for a fence/guide.

So last night I got the back is cut out, today I've cut the two sides and am about to start on the main shelves. I figure once I get the main assembly dry fit I'll have an easier time determining exactly what size/how many drawers I want.

Anyway, here's a quick sketch of the general idea. Sort of to scale (1" = 1') for overall width/length.
https://sphotos-a-sjc.**.fbcdn.net/hphotos-frc1/995442_3396040557077_1100671586_n.jpg

Got the back and sides cut out from the first sheet of ply.

Put the new top to use already.

Sides are 23 1/2" x 33 7/8"
Back is 52 1/2" x 33 7/8"

https://sphotos-a-sjc.**.fbcdn.net/hphotos-prn1/553096_3397477633003_1644618748_n.jpg

 

[98TJ]

Got the main portion of the cabinet dry fit. Now to sort out partitions and drawers.

iPhone camera distorted things a bit (top looks like it's sagging, bottom shelf is bowed up, middle shelf is straight) but everything is straight.

 

[turbowoodworker]

Very nice design and execution. is that the Rouseau router base kit?

 

[98TJ]

Thanks.

That's an old JessEm Rout-R-Lift FX.

They have since been replaced by the Rout-R-Lift II

 

[Krokodil]

Very nice work! Good to your Were screwdrivers are still in service.

 

[98TJ]

Very nice work! Good to your Were screwdrivers are still in service.

Thanks, man.

Love those things. Much nicer that the SO hard-handle drivers everyone raves about. Better grip.

I was watching for the Secret Santa in 2012, didn't see it. Did they do it last December? I purchased some items in advance for this year but didn't see it.

I spent a little time finalizing partitions for everything. It's all still dry fit together.

Up top, on the left, will be three 33 1/2" wide drawers that will be 21" deep.

Top right will be some small drawers for router bits and wrenches. Above them will be a hidden area for power cable that will keep them out of the drawers.

Bottom section will have two drawers per side, 25" overall width, 21" deep.

Also picked up some 2 1/2" dust collection items so I can make a T from the router chamber to the fence.
https://sphotos-a-sjc.**.fbcdn.net/hphotos-ash4/998922_3404532969382_162077810_n.jpg

Started work on the inside of the router chamber so dust doesn't collect in the corners. Got late here and I didn't cut the back wall (neighbors). Kept the router chamber as compact as possible in an effort to reduce the volume of air the Shop-Vac has to pull from the chamber. This also maximizes drawer space.
https://sphotos-b-sjc.**.fbcdn.net/hphotos-ash3/64320_3404944059659_164498449_n.jpg

https://sphotos-b-sjc.**.fbcdn.net/hphotos-ash4/1003743_3404944259664_1733960233_n.jpg

I was looking at drawer slides for this thing and my wife said "It has to have soft-close drawers. You don't want them slamming shut, your tools will move in the drawers."

 

[coolreed]

Looks like you are building a very nice router table. I really like the top.

I think I would install a few gussetts in the corners to reinforce the basic playwood box.

Best of Luck and Happy Woodworking

 

[R.Anderson]

looking forward into seeing the table finished, looks good.

also . . .

I spy a shop stool that should be posted in "Let see your alternative style shop chairs" thread. Finally a use for those aluminum crutches collecting dust and I just happen to have a bike rim with no tire saying around somewhere too

 

[98TJ]

Looks like you are building a very nice router table. I really like the top.

I think I would install a few gussetts in the corners to reinforce the basic playwood box.

Best of Luck and Happy Woodworking

Thanks, man.

I plan on adding bracing, just need to get to that point. Everything is dry fit right now.

looking forward into seeing the table finished, looks good.

also . . .

I spy a shop stool that should be posted in "Let see your alternative style shop chairs" thread. Finally a use for those aluminum crutches collecting dust and I just happen to have a bike rim with no tire saying around somewhere too

I'm anxious to get it finished. Once I had the cabinet dry fit and put the table on top I wanted to just start using it. I've been running the router while in the table to cut pieces and, each time I do, I'm testing dust collection under the router. Seems I'll be good.

That shop stool was a college art project.

Been busy building and fitting some new parts in place.

I wanted my on/off switch for the router and vac up front but didn't want the cables laying all over. The solution was to build a partition above and behind the small drawers.

Also made drawers for the 1/4" and 1/2" shank router bits.

Here's the 1/4" drawer. Need to drill the 1/2" drawer and assemble it.

https://sphotos-a-sjc.**.fbcdn.net/hphotos-ash3/1097945_3409641817100_1013961904_n.jpg

The work area. No table saw so I'm using that Kreg Rip-Cut. Not a huge fan, but it's getting the job done.

 

[Mandres]

Looks great. Was it nerve-wracking routing out that pocket for the router plate? Did you make a template or something?

 

[98TJ]

It wasn't bad. I just traced the lift onto the bench, drew the small opening, drilled four holes at the corners for the smaller opening, then ran the jig saw between the corners for the rough cut then stuck some boards to the bench with template tape and got to cutting. No bushings, just a template bit with a bearing.

For the recessed area where the lift sits I cut all of the sides with the boards for guides and did the corners freehand, making multiple passes to get the depth just right.

 

[98TJ]

Didn't get much done today.

Did manage to get the maple cut for the rails, stiles, and toe kick. They're cut to rough length right now and a hair (1/32") over finished width.

Also managed to get one set of drawer slides installed tonight. I wanted to get these three installed during dry fit (all of the panels are assembled with Kreg pocket hole screws) so I can make sure they work before everything is glued up. It's a PITA working in that small opening. I should get the rest of the drawers installed tomorrow then it'll be time to blow it apart and start gluing it up.

 

[98TJ]

Grabbed 6-32 Tee nuts for the small drawers. These are much better for the 1/4" MDF sides than the stock screws. Stock screws are junk for pretty much any use.
https://sphotos-a-sjc.**.fbcdn.net/hphotos-ash3/1098000_3414368975276_1590129497_n.jpg

https://sphotos-a-sjc.**.fbcdn.net/hphotos-ash4/1005803_3414369135280_541407151_n.jpg

Mounted the top drawer.

https://sphotos-b-sjc.**.fbcdn.net/hphotos-prn1/1098202_3418461357583_1506156589_n.jpg

Needed to go get a belt for the belt sander. Ace Hardware had everything the store at 75% off. I grabbed 26 drawer pulls, 28" x 30" acrylic sheet, some hinges, and a couple of other things. $37.

Also got the back wall of the router chamber built and in place. No corners with dead air so dust can collect.

 

[98TJ]

Blew it apart, glued and re-assembled it all.

Bottom partition is in, 3/4" maple for rails and stiles attached, and the front, left, and back edges (top and bottom) of the top were hit with the 1/4" round-over bit. Also made the door frame for the router chamber.

Got the door built, cut the acrylic to fit, drilled four 1" holes for air inlet, installed hinges, applied some Watco Danish oil to the rails, stiles, and the door frame. Also installed a small light for the router chamber.

Does great for keeping the dust out of the inside, but I'll give the inside a few coats of clear to reduce surface friction and help the few bits of reluctant debris to move with the airflow.

To keep the door closed I used some strong little magnets I found forever ago at the craft store. Just drilled a 3/16" hole and pressed them in.

 

[KCarGuy]

That is a Bad *** Router Table.
I love your Ideas and the quality of work that you have put into it.
I may need to steal some of your Ideas.
Great Job and Thanks for sharing.

 

[98TJ]

Thanks, man.

I got the maple drawer fronts on the three small drawers for the side a few days ago. Used the same Watco Dark Walnut Danish oil on the drawer fronts that I'm using for the rails, stiles, and exterior ply surfaces.

I used the 3" wood drawer pulls I picked up for 99 cents each at a local Ace Hardware that was going out of business. A Home Depot came in less than 1/8 of a mile from the place and I kept an eye on the sale prices. Got 26 drawer pulls for 75% off. Used Watco Natural Danish oil on the drawer pulls.

Also made a small panel to mount the on/off switch for the router. I didn't want a large switch like others I've seen and I wanted a safety key in the thing so kids couldn't turn the thing on if they saw the switch and got a bad case of "What's the big red button do?" I know my kids won't mess with it, but if friends come over, I want to make sure the place is safe. When the switch is on the router, light, and Shop-Vac all come on.

I used a Kreg two outlet switch that is sold for their router tables, removed the switch and extended the switch wiring, then used a 3-prong plug to hardwire the light. I also ran power for an outlet on the back of the cabinet so I can plug the Shop-Vac into the outlet and it will kick on/off with the switch.

https://sphotos-b-sjc.**.fbcdn.net/hphotos-frc3/970352_3441612376344_592014624_n.jpg

The router chamber has been given a few coats of satin finish Minwax Helmsman spar urethane to reduce surface friction and keep the dust moving.

 

[lilscorpion]

Very nice. Can you step back a few feet and share a pic of the finished unit?

 

[98TJ]

Very nice. Can you step back a few feet and share a pic of the finished unit?

Thanks, but it's not finished yet. Still need to make and install more drawers, build the subframe and mount the casters, and build the drawer fronts for the rest of the drawers and install them.

 

[Jim B]

Geez. Just when I thought I I'd stolen all the ideas I need to steal from this site this project comes along. Especially like the dust collection setup. Nice job!!

 

[Texon Stormy]

I'm jealous,the quality and precision are simply awesome,thanks for sharing.Looking forward to seeing the things you build using it.

 

[98TJ]

Got some work done today and I'm loving this table. Having the ability to have a piece of work hang off any side is nice, but having the T-track with clamps makes it that much better. I've been clamping the work down with the T-track and clamps and just letting it hang of the edge for cuts. Clamped the Kreg pocket hole jig to the bench and made short work of a big drawer tonight.

Plenty of table means plenty of support for large items on the router. Since I'm cutting with the circular saw, I'm cutting slightly oversize and then using a straightedge and a template bit to trim all the pieces to their exact sizes. Routed this assembled drawer as you see it.
https://sphotos-b-sjc.**.fbcdn.net/hphotos-prn2/1235123_3457810301282_1361967608_n.jpg

That was a good time to see how well the dust collection setup is working.

Here's the inside of the router chamber. Clean.
https://sphotos-b-sjc.**.fbcdn.net/hphotos-prn2/1146693_3457626016675_57255051_n.jpg

The top side was messy, but that will be much cleaner when the fence gets here and I get it installed.

Got the biggest drawer installed on 22" full-extension slides. Built it from 3/4 maple/birch ply for the bottom and 1/2 for the sides and back. Most likely overkill, but I don't want it to sag. I have another set of slides to go on. These are rated at 75lbs so a little redundancy won't hurt. This is 32" wide, 23" deep, and 8" tall. All of my DeWalt 18V stuff fits in here with room for other large items.
https://sphotos-a-sjc.**.fbcdn.net/hphotos-ash3/536794_3457865502662_1265005778_n.jpg

 

[jesse72]

Man that is a great router table, awesome work! Also really like your US General bench/cabinet set up!

 

[Fizbin]

That is indeed a great looking bench and you certainly put a lot of thought and work into it... very nice!

I was wondering why you decided to go with all **** joints, though. Wouldn't at least a few dados here and there be more sturdy? I'd hate to see you exert all of that effort only to have the thing start separating a couple of years down the road.

 

[98TJ]

Thanks, guys,

Fiz, we're still military so we have a move to look forward to every three years or so. With dados if anything gets damaged in shipping, both pieces are likely ruined. If something comes loose on a **** joint any repair work will be much easier. Kind of bad to think that way, but it's the reality of military moves. something always gets damaged. I thought about dovetails on the drawers, but I'm using ply.

By the time it is done it should be rock solid.

 

[98TJ]

Very nice. Can you step back a few feet and share a pic of the finished unit?

These are the best I've got so far. (see below)

It's on 2 1/2" dual-locking casters now. Got some drawers made, some drawer fronts made as well. Need to cut the top drawer front to size and get it installed tomorrow. It's clamped up now.

Three drawers and fronts left to make.

https://sphotos-a-lax.**.fbcdn.net/hphotos-prn2/1236448_3497248007200_1489860375_n.jpg

Next to my 6' Gladiator maple topped bench.
https://sphotos-a-lax.**.fbcdn.net/hphotos-frc3/1238955_3497247887197_342203495_n.jpg

 

[superspec]

Your work always amazes me.

The old radio inspired me to do my own.

 

[Fizbin]

Fiz, we're still military so we have a move to look forward to every three years or so.

It all makes sense now. I was an army brat until the age of 13 and hated every move. Just when you finally get settled in and comfortable it was time to pack up and hit the road!

 

[4EyedTurd]

Awesome job!

 

[98TJ]

Man, I forgot about this thread.

Thanks, guys.

I've got it pretty much wrapped up. Photos are warped - camera phone.

https://scontent-a-lax.**.fbcdn.net/hphotos-frc3/1459178_3753926223995_1035014563_n.jpg

https://scontent-b-lax.**.fbcdn.net/hphotos-ash4/1463104_3753926343998_1812335521_n.jpg

Kreg router table fence. I like this style of fence. Can even use it as a jointer at 1/16" and 1/32" depth of cut.
https://scontent-b-lax.**.fbcdn.net/hphotos-frc3/1466293_3753926464001_1972881155_n.jpg

Kids helped wax the top.
https://scontent-b-lax.**.fbcdn.net/hphotos-prn2/1384347_3675227736582_1512175420_n.jpg

 

[jesse72]

Thanks for the finished photos! It looks great and Im sure it works awesome. Your work is well done!