Aluminium Router Table

**Bushmiller** · 18th November 2016, 11:39 PM

Just recently I acquired six aluminium plates of a suitable size to make a router table. I put them up for sale in the Market Place, but one I decided to go ahead with and make up a a table.

The plate is 975mm x 570mm x 38mm. It has a number of holes in it mainly around the periphery. Some years ago I bought an Incra aluminium plate suitable for my Triton router, but have never got around to putting it in a table.

Aluminium Plate 001.jpg

I prefer to post the finished product, but this one is a WIP, but I have to state in advance that there might be a few delays in progress. I guess there will be no alternative but to post warts and all.

Incidentally I initially thought this material was stainless steel, but woke up to it being aluminium when I twigged it only weighed 56Kg instead of 165Kg!

I don't have any specialised metal working tools so whilst I was quietly confident I would be able to work the ally, I had no previous experience in the medium.

I marked out the area to be cut about 10mm smaller all round than the Incra insert plate. This was so I could form a rebate at a later point. I drilled pilot holes having estimated the radius at 38mm:

Alluminium Router Table 005.jpg

I used a drilling jig to keep the drill reasonably straight.

I had planned to use a hole saw as the next step. I had a new 38mm saw, but it was hopeless. Clogged and just would not cut even lubricating it with kero.

I then tried two reduced shank twist bits with the larger being 1".

Alluminium Router Table 006.jpg Alluminium Router Table 007.jpg

They just raced through. I then opened out the hole to 38mm using a "super drill" which is just a fly cutter style:

Alluminium Router Table 008.jpg Alluminium Router Table 009.jpg

As it happens, I probably could have got away with just the 1" drill but more on that later.

Then I needed to cut between the holes with a circular saw. There was an immediate problem there as my saw just would not cut despite having a metal cutting blade. A closer inspection showed I needed a new blade. Mainly the teeth were missing, but those that were present were severely damaged. The local hardware had a suitable blade but I was not prepared to fork out $135 for it and ended up buying a Bosch blade (185mm) for about $45. It worked like a beauty and just sliced through the ally.

Alluminium Router Table 010.jpg Alluminium Router Table 011.jpg Alluminium Router Table 012.jpg Alluminium Router table 013.jpg Alluminium Router table 014.jpg

I cut from both sides and made up a guide for the saw as seen in the second pic. There was just a small bit remaining to cut by hand as the circular saw would not reach. I used an old Simonds metal cutting hand saw (14ppi), but equally I could have used a jigsaw.

Alluminium Router table 016.jpg Alluminium Router table 017.jpg

I then had to form a rebate which I did with a router bit, but this is when I discovered that I had measured the radius of the Incra plate incorrectly. It was too large. I will be able to rectify this, but not until after I get back from the Katoomba GTG, which will be at the end of November. More then.

Regards
Paul

**Bushmiller** · 19th November 2016, 08:00 AM

Just another quick pic or three before I head off on the first leg to Katoomba for the GTG on Sunday.

Aluminium plate 006.jpg Aluminium plate 008.jpg

I used a rabeting bit with a selection of guide bearings gradually taking a little more off with each pass. it worked really well and no damage to the bit, which I was prepared to accept

Aluminium plate 007.jpg

Regards
Paul

**wheelinround** · 19th November 2016, 08:30 AM

Paul not bad job done on the routing finish shame about the size tho. It will be one heck of a router table top thats for sure.

Safe trip.

**Chris Parks** · 19th November 2016, 04:52 PM

I have never understood why anyone would prefer MDF over aluminium for router table top. I wouls want to have it anodised though as I suspect black oxidation transfer onto the timber will become an issue.

**Simplicity** · 19th November 2016, 05:25 PM

Originally Posted by Chris Parks

I have never understood why anyone would prefer MDF over aluminium for router table top. I wouls want to have it anodised though as I suspect black oxidation transfer onto the timber will become an issue.

I totally agree Chris
But if you we're buying either piece at retail prices.
The MDF would certainly sent you home a lot happier than the Aluminium would.

Matt

**Bushmiller** · 28th November 2016, 08:45 PM

Chris

I had not considered the oxidation issue. At the moment the plate has what I would describe as a baked enamel finish, which I had planned on removing, but perhaps I won't do that now.

Regards
Paul

**crowie** · 28th November 2016, 09:58 PM

Looks very good Paul,
Watching.... Peter

**Rod Gilbert** · 29th November 2016, 09:39 AM

Very impressive Paul this should prove to be a brilliant router top

good luck with the rest of the job I am sure it will be a great asset in you're workshop.
Regards Rod.

**Cliff Rogers** · 29th November 2016, 10:16 AM

I made mine from 10mm thick Ali, covered the top with bathroom laminex, it covers the unwanted holes & stops the Ali from staining the timber.
photos are here. Challenge to Create the Ideal Router Table

**Xanthorrhoeas** · 29th November 2016, 12:28 PM

I have a Festool aluminium router table with attached sliding table. It is anodised but I still found it would mark some timbers so I made a new table from 2 x 18 mm marine ply plus a layer of mdf (can't remember the thickness) for stability (although I don't like mdf normally). I put a laminex top on it and a router lift for my Triton. Yes, I know, the Triton has a built in lift but I find the chain-drive lifter much better.

I find this table much more useable and user-friendly than the Festool much more expensive set-up. Your al top is much thicker and larger than the Festool table so should be really stable but, like Cliff Rogers, I strongly suggest that you consider putting a laminex top on it - and if you do that you will need to allow for that when you rebate for the router plate.

**Bushmiller** · 29th November 2016, 12:39 PM

Cliff

Thank you for reminding me of your table, which I had seen before and in fact I replied to your post, but it had fallen off the fleshy tablets of my mind so your post is most opportune.

Regards
Paul

**Bushmiller** · 29th November 2016, 12:44 PM

Xanthorrhoeas

I have in fact got a piece of Laminex that I had put to one side for the router table I was going to make before I acquired the aluminium slabs. I should be able to allow for the difference in rebate depth on the adjustable leveling screws that are part of the Incra plate. If I run out of travel I will get some longer screws. As an alternative I could pack out the rebate with Laminex to compensate.

Regards
Paul

**Xanthorrhoeas** · 30th November 2016, 05:44 PM

Sounds great Paul,

You will end up with a very spiffy router table.

David

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