ondablade
5th September 2009, 10:24 AM
Hi guys. I've just bought an LS 25 positioner and Wonder Fence set up to use with an Incra plate and De Walt DW625E with a Router Raizer on a router table, and will shortly be getting stuck in to building it.
Flatness and high precision will be important, as i want to use it for joint cutting.
Lots of great design ideas and examples of this sort of work here, e.g. http://www.woodworkforums.com/showthread.php?t=47602
I'd like to surface the table top with laminate or similar to minimise friction, but am unsure what to do about the core.
There seem to be a number of choices available (each with their own potential isues), i've listed some below.
What do you guys think is best/are the pros and cons?
1. Section of laminated chipboard worktop - will it stay flat over time (chipboard tends to sag), and the possibility of swelling at the exposed edges in presence of even small amounts of moisture must be high?
2. Waterproof WBP grade birch ply, or MDF instead of chipboard - better, but maybe quite heavy in relation to its stifness/
3. Torsion box /lattice type frame in MDF or ply, with MDF or ply skins top and bottom - very stiff if the webs in the lattice are deep, but how flat can it be built?
4. Sheet of 12-15mm polished granite, marble or even thick float glass (could crack or chip if something is dropped on it), laid over a metal frame (bolted up to avoid distortion - maybe from the Item aluminium extrusion system?) - getting expensive, and cutting the hole for the router or your router lift handle might be problematical, but it should stay flat? Perhaps not that expensive if sourced from your local stone fireplace or kitchen manufacturer for whom this is a stock material, they should be able to cut the ope and smooth the edges??
Other options? e.g. something like Lexan polycarbonate sheet over a metal frame?
Flatness and high precision will be important, as i want to use it for joint cutting.
Lots of great design ideas and examples of this sort of work here, e.g. http://www.woodworkforums.com/showthread.php?t=47602
I'd like to surface the table top with laminate or similar to minimise friction, but am unsure what to do about the core.
There seem to be a number of choices available (each with their own potential isues), i've listed some below.
What do you guys think is best/are the pros and cons?
1. Section of laminated chipboard worktop - will it stay flat over time (chipboard tends to sag), and the possibility of swelling at the exposed edges in presence of even small amounts of moisture must be high?
2. Waterproof WBP grade birch ply, or MDF instead of chipboard - better, but maybe quite heavy in relation to its stifness/
3. Torsion box /lattice type frame in MDF or ply, with MDF or ply skins top and bottom - very stiff if the webs in the lattice are deep, but how flat can it be built?
4. Sheet of 12-15mm polished granite, marble or even thick float glass (could crack or chip if something is dropped on it), laid over a metal frame (bolted up to avoid distortion - maybe from the Item aluminium extrusion system?) - getting expensive, and cutting the hole for the router or your router lift handle might be problematical, but it should stay flat? Perhaps not that expensive if sourced from your local stone fireplace or kitchen manufacturer for whom this is a stock material, they should be able to cut the ope and smooth the edges??
Other options? e.g. something like Lexan polycarbonate sheet over a metal frame?