Thread: Phenolic resin sheet.

Trend make one and MIK stock it. You could make one, but without cnc machining you wouldn't end up with as good a product and the plastic isn't cheap. The ready made ones come with insert rings and the like and are simple to set up.
Another name for the stuff is 'ultra high molecular weight' plastic (UHMW) - available from "industrial plastic" suppliers.

Robert,

I also looked as using phenolic resin but after finding out it would cost in the range of $400-$600 for a piece large enough for a router table (another reason is that Phenolic is very hard to machine as Eastie mentions. I have heard that it kills router bits). I ended up using 2 pieces of melamine faced MDF one on top of the other.

So that I did not have to worry about future warping of the top, I braced the underside with steel bars. As for inserts, I opted to buy a new Model Triton router plate as a spare part. This came with the clamps (particularly suited to the Triton Router I have) and reduction rings. I fitted this into the table, again re-enforcing with steel bar. For the fence, I fitted an Incra Jig Ultra Lite (which is just fantastic) which I raised up and fitted a high fence face with sliding cheeks.

Attached is a picture of the completed table and cabinet. It has integrated dust collection through the fence and plate into the cabinet. A 4" dust port is connect to the cabinet at the side (back?!?!). With this setup, I get virtually no dust/chips.

Also, due to my limited workshop space (it used to be big but seems to be slowly shrinking, particularly after Wood shows), I have fitted my metal vice and Bench Grinder on the back (side ?!?!).

I got a lot of the ideas for the unit from the web particularly Dizzy's site which you should check out at http://home.pacbell.net/jdismuk/routertable.html. While your there, have a look at his Cyclone he made. I am attempting to make one of these at the moment.

Good luck building yours,

Robert

I purchased my phenolic insert plate from Jesada (in Australia). From memory it was about $60. Nicely machined, comes with 3 insert rings.

Look it up on their website:
http://www.jesada.com/australia/mall.../web_store.cgi

Try direct to router table accessories):
http://www.jesada.com/australia/mall...id=8152404_894

Regards from Perth

Derek

Thanks for the replies.
I had a look at the instructions for making a router table top at the Gigkins site today. It suggests that the top be made of two sheets of Lamipanel supported by an mdf base sheet.
What is Lamipanel?
I looked it up on the net and discovered that it is used to clad wet areas inside houses, but the site didn't tell me what it is made of.
Can anyone enlighten me???

Hi Robert
Im not sure but I think that lamipanel is a laminated board made from highly compressed paper and ??Resin?? not unlike laminex used for benchtops but about 5-6mm in thickness....dont quote me tho! Sorry cant be of more help:confused:
just found laminex site for u .....www.laminex.com.au/ hope this helps on sizes,cost etc

Hello Robert,

I renovated my bathroom several months ago. We had lamipanel on the walls and replaced it with tiles. Lamipanel is very similar to Laminex, but about 4mm thick. I recycled some to cover som workbench tops. It's not too bad and provides a slippery surface so your workpieces slide on it quite nicely. Pity your not in Darwin, I have a few spare bits big enough for a router table.

All the best - Peter

Regarding the phenolic insert,

Couldn't find any so I'm using 10mm PVC perspex from nearby perspec dealer. Bloody awesome - no flex, hard as a rock. Only $27 for 1 sq ft. Range of colours too!!

Wad.

Hi,

I totally agree with the last reply. 10mm perspex has very little to no flex especially when using a piece small enough for a table insert. But more important, its safer to work with. Phenolic sheet is extremely toxic to machine. Both the fumes and the dust are toxic. If you want to use it get someone who has the proper equipment to machine it, or are too stupid with no concern to their health.

Glen

[QUOTE=WoodWad]Regarding the phenolic insert,

Couldn't find any so I'm using 10mm PVC perspex from nearby perspec dealer. Bloody awesome - no flex, hard as a rock. QUOTE]

Wad,

PVC and perspex are different beasties. Whilst feeling quite stiff, it had been my experience that over time the material will creep, even over short distances. PVC may also become embrittled.

Good luck with your router table. You will need to ensure it is very well supported.

Have a look at Carbatec's new insert plate (similar to the Trend and Jesada plates) page 30 in the new catalogue Says it is made of ABS plastic.
Good value at $45.00 with two removable rings.

Thanks for reminding me, gotta get a hold of that new catalogue

I made my 300 X 300 insert out of 10 mm phenolic sourced at a local industrial plastic supplier called AB Plastics in Hallam, Vic.

Found it easy to machine with standard carbide router bits, stunk like a bastard whilst being machined so good idea to have area well ventilated while working on it.

Marked out mounting holes from router subbase, atached router and plunged progressively larger bits through to form central hole.

It is extremely rigid and doesn't flex at all with my Hitachi M12V hanging off the bottom. I mounted the router using some longer countersunk M5 (from memory) allen headed high tensile screws (high tensile so the allen heads wouldn't chop out when being frequently undone for handheld use).

Cost $40 cash about 2 years ago, which makes the Jesada (?) plate at $60 or $70 pretty good value I reckon.

My only issue with any plastic insert is the amount of plunge depth you lose from the plastic thickness. This is not an issue most times but I have one bit I loctited a bearing on the shank to use with my homemade dovetail jig (like the Katie/Gifkins jigs), but the router must be used handheld as the bearing doesn't clear the plate at full plunge in the table.

For this reason I think a steel or even aluminium plate would probably be better, plenty of strength even at minimal thickness, you would just need to figure out a way of fitting insert rings.

I thought it was a great idea someone who sourced the Triton router plate and clamps etc as a spare part and built their table around that, my only problem with that would be the issue of the insert rings not being flat with the plate, Triton seem to have engineered it this way deliberately and play this down but I think it is still an issue. I purchased the plate, rings, & hardware for a router planing jig and even after looking at a number of rings I still wasn't real happy with them.

BTW, lamipanel is a thicker version of laminex, both are sometimes called high pressure laminate, they are both made from phenolic resin (this is the black core you can see even in coloured sheets of both) and explains the high strength in them, particularly when several sheets are laminated such as in Roger Gifkins router table idea.

Another BTW, lamipanel is a different beast to Ceramilite, which is an embossed sheet that looks like a tiled wall, and available at Bunnings. This has a hardboard core like Masonite with a waterproof proprietary coating front & back.

Cheers..........Sean