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  1. #1
    Join Date
    Apr 2001
    Location
    Perth
    Posts
    10,810

    Default New router table and router table fence

    Here's the router table and router table fence I have been building. There is a little more work to do on the micro-adjuster, which is coming from AliExpress, as well as the dust extractor for the (2 1/4 hp) Elu 177e router I use. But for now, the rest is done.


    This is a very full-on set up. What is relevant is that it did not cost much (don't include the cost of the JessEm guides, which are excellent but a little luxury). It is difficult to total, as some parts, such as the aluminium insert plate, was purchased about 3 years ago, as was the Router Raizer lift, and the MuscleChuck router bit change.


    The base for the router table was a laminated high pressure MDF kitchen bench off cut from a kitchen maker ...





    This was build into the outfeed of my Hammer K3 sliding table saw ...








    These aluminium plates are excellent. After 3 years of hanging the heavy Elu, there is no signs of any dips. The surface remains flat, flat.


    The Elu below, minus handles, with Router Raizer attached ...





    Above the plate, the MuscleChuck allows for changing bits and easy bit-holding. I built a handle for the Router Raizer from a cut-down socket wrench. This enable fast spinning as well as fine adjustments with the fence close by.





    The heart of the fence is made for 8020 extruded aluminium (80mm high and 20mm wide). I comes in 1m lengths, and this fence is 600mm long.





    Note that the slots of this extrusion use different T-bits ...





    The only other part I bought in were the sub-fences, since these are phenolic-coated, and the dust port.





    The subfences. Also note that the dust collection port in the mainfence was made with a 2 1/4" hole saw ...





    The Jessem guides, and the bit guard I made ...








    Made in two sections and superglued together ...





    The rear of the fence, with the dust port, and sub-fence adjusters ...





    The reason for bolting on the dust port was not simply to make it possible to remove, but this enabled the T-track to be plugged ...





    The (very stiff) UHMW fence bracket is temporary ...





    and will be replaced by these brackets with fine-adjuster (only needed on one side) ...





    There is adjustment built into the brackets to ensure that the working side of the fence is square to the table ...





    I hope that this provides some ideas for your build.


    Regards from Perth


    Derek
    Visit www.inthewoodshop.com for tutorials on constructing handtools, handtool reviews, and my trials and tribulations with furniture builds.

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  3. #2
    Join Date
    Apr 2001
    Location
    Perth
    Posts
    10,810

    Default

    Two more tasks completed with the "new" router table ...

    Firstly, the below-table dust collection system was completed. This adds to the dust collection in the fence.

    The Elu 177e router, which is used in this table, did not come with dust control. I have two of these routers, the first one purchased 25 years ago. I guess that dust control was not a concern then. However, when Elu was taken over by Black & Decker, their top-of-the-line router became the DeWalt DW625. This was a straight copy of the Elu 177e, and it did come with dust control. So, for those out there with a Elu and wanting dust control, get the part for the DW 625.

    With a slight modification (to seal any gaps), this was added here ...




    The second modification was to remove one of the springs. Plunge routers in a table have to fight their springs. I considered removing both springs, tried this, however it felt too loose - the router has to rely on its weight and gravity to open. One spring adds a little tension and is a decent compromise.

    The spring which remained is the one alongside the Router Raizer ...




    Up-and-down travel is now smoother and less effort.


    This is the dust collector from above the table ...



    It does not impede above-table bit changing ...



    A tip, for those using a router table in their table saw extension, is to keep an undrilled router bit cover to prevent saw dust dropping down into the arbour of the router ...



    Regards from Perth

    Derek
    Visit www.inthewoodshop.com for tutorials on constructing handtools, handtool reviews, and my trials and tribulations with furniture builds.

  4. #3
    Join Date
    Sep 2016
    Location
    Bentleigh East
    Age
    50
    Posts
    423

    Default

    Hi Derek, quick one: do you use different inserts with cut outs to help with dust extraction? And where can you find such plates with matching inserts that don't say Incra or anything else on them (which probably cuts the price to half)

  5. #4
    Join Date
    Apr 2001
    Location
    Perth
    Posts
    10,810

    Default

    Spyro, I looked at the various table plates when I began the rebuild of the router table. One of the factors which encouraged me to just keep the aluminium Timbecon plate ("Sherwood") was the lower cost of the inserts. I believe that the Carbatec plate and inserts is the same and rebadged. The inserts are not cheap - $24 for a blank, and $109 for a set of four of varying sized cut outs.

    The cut out is important to match to the size of the router bit for safety, as well as above-table dust collection, which I suspect does more collecting of dust than below-table.

    I keep a non-cut out insert on the plate when the router is not used.

    Regards from Perth

    Derek
    Visit www.inthewoodshop.com for tutorials on constructing handtools, handtool reviews, and my trials and tribulations with furniture builds.

  6. #5
    Join Date
    Sep 2016
    Location
    Bentleigh East
    Age
    50
    Posts
    423

    Default

    Thanks Derek
    I also suspect the fence extraction is generally more efficient, but what happens when you're not using the fence, or the cut you're making is in the bottom of your work piece... that's why Incra sells those as part of the "cleansweep downdraft dust collection cabinet"
    INCRA TOOLS :: Precision Fences :: Router System Accessories :: INCRA CleanSweep Dust Collection Cabinet


    I've heard it works well even without fence extraction, and most importantly it works with or without the fence

  7. #6
    Join Date
    Apr 2001
    Location
    Perth
    Posts
    10,810

    Default

    I spent a little time exploring the combined above-and below table dust collection. The Elu router was modified to fit the DeWalt dust port (in above post).

    I was quite interested in the Miles set up ...




    I bought one, but it did not fit the Elu router (I have it for sale half-price, if anyone is interested).

    The concept of two hoses is the way to go, and it was just necessary to match up a hose system to the existing Elu outlet. To do this I purchased the Festool twin hose ...







    One hose goes into the dust port of the fence ...





    The other goes into the dust port at the router ...



    And they connect via a Y into the vacuum cleaner ...



    Regards from Perth

    Derek
    Visit www.inthewoodshop.com for tutorials on constructing handtools, handtool reviews, and my trials and tribulations with furniture builds.

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