Building the Tabletop

The tabletop is pretty much a miniature of the Custom Router Table Top. The chapter of that name, which begins on page 156. details just how to construct such a tablctop.

1. Cut a hole in one ply for the router. Like the generic tabletop. this table has a two-ply core. The layers, however, are '/>inch plywood (not 34-inch). The router mounts directly to die tabletop—diere's no mounting plate: it fits into a '/¿-inch-deep recess in the underside. Now you can excavate the recess after assembling the tablctop, but it's a heck of a lot easier to simply rout a hole in one ply, then glue-laminate the core.

Lay out the ccnter of the hole, drill a pivot hole, and use the Trammel Baseplate (see page 39) on a plunge router to cut the opening. Fit the opening tightly to the router you will be using in the router table.

tape or packing tape (or with carpet tape between them). Lay out the hinge-pin hole and the shape of the hinges on the top workpiece.

Drill the hole for the hinge pin.

With the two hinges still taped together, miter the ends, as shown in the drawing, then cut the main taper. This last cut is done most easily on the band saw. but I did it on the table saw using a tapering jig. Peel off the remaining tape, separating the parts, and sand them, softening the edges.

De-Sta-Co #TC-215-U toggle clamp

Commercial folding lid stay


!4"-dia. hole for lag-screw hinge pin


---- - 12/4"-\--




— m-—

8 H"

I — 1"


/ — r—-


tress.With a back saw and chisel, trim the buttress. Repeal the process on the other side.

Chuck a ^6-inch bit in a portable drill. Hold a hinge in place against the base unit. Guided by the hole in the hinge, drill a pilot for the lag-screw hinge pin. Drill the second hinge-pin hole.

Temporarily mount the hinges on the base unit. Try to lift the hinge, and you'll see there's still interference between the buttress and hinge. Mark the material that must be removed, then pare it away.

5. Attach the hinges to the tabletop. Set the tablctop on the base, and carefully align so it overhangs the base exactly the way you want it to.Then scribe along the base ends on the tabletop. In turn, hold each hinge in place, and scribe along die ends on the underside of the tabletop.

Lift the top off the base and lay it on your workbench, bottom up. Set the hinges on the tabletop. about Vic inch outside of die lines. Drill and countersink pilot holes, and drive 1%-inch drywall screws through the hinges into the tablctop. Three screws in each hinge is enough.

6. Install the toggle clamps. The opdmal position for the two toggle clamps w ill vary from router to router. Hie locations and orientation shown in the drawing Tabletop Detail works with a Porter-Cable 690 router, but they may not with a different model or brand. With the tablctop still on the workbench, set your router in place, and try the clamps in different locations. Don't be content to find a spot that works if the clamps are closed. You have to work the clamp to ensure that the spindle doesn't hang up on the body of the base or the depth-control knob or some other protuberance on the router.

When you've determined the best locations for the damps, attach each to the tabletop with four *H X 1-inch panhead screws.

Adjust the spindle of each clamp so the router is held firmly in place. Then remove the router and set it aside until the router table is completed.

7. Mount the tablctop on the base unit. Set the tabletop atop the base unit. Fit flat washers on the hex-head lag screws, and insert one through each hinge into the pilot for it. Drive the screws with a wrench.

8. Install the stay. After experimenting with several different homemade props for the tabletop. I settled on a commercial folding lid stay. The folding stay cost me only $2. and it keeps the tabletop up until I am consciously ready to lower it.

To install the stay, you will have to experiment to find the best location. The drawing Lid Stay Detail provides a general idea of where to locate it.

9. Install the toggle latches. One toggle latch is mounted on each front stile. The strikes are installed on the underside of the tabletop.



Fender washer

Position stay where strut tip will clear stile as tabletop is

Fender washer



27 VS





Cutout for bit | \/A- for clamp bolt - ^ 1 for alignment screw

PATTERN I square = Va

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Woodworking Tools and Installation Tips

Woodworking Tools and Installation Tips

There are a lot of things that either needs to be repaired, or put together when youre a homeowner. If youre a new homeowner, and have just gotten out of apartment style living, you might want to take this list with you to the hardware store. From remolding jobs to putting together furniture you can use these 5 power tools to get your stuff together. Dont forget too that youll need a few extra tools for other jobs around the house.

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