Horizontal Router Tabl

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__________w____________ extends only a foot beyond the end of the saw table—that's all. It isn't an extra stand that needs its own floor space; it's sharing the table saw's floor space. The swing arm pivots up when you want to raise a panel or cut a tenon but drops conveniently out of the way when it isn't in use. Its presence doesn't impinge-on other woodworking operations.

The setup takes good advantage of the saw's mass, and it makes excellent use of the saw's broad, flat tabletop.You don't need a high-powered router for it; it's one setup in which any router will work (which is emphatically NOT true of regular router tables). As designed, this horizontal router mounting overcomes a fundamental shortcoming of most horizontal mountings: fine adjustment.

The design is clear-cut. A plywood support panel is attached to the rim of the saw's extension wing, and it's anchored to the saw housing so it is perfectly perpendicular to the saw table. Bolted to the support panel is a thick swing arm, which holds the router. As its name implies, this arm swings on a bolt, raising and lowering the router and bit. Fine adjustments to the cutting depth are made through a jaekserew. which can move the swing arm almost infinitesimal amounts. You adjust the bit height coarsely, by measuring the bit position as you move the arm with your hand. Then you move the jaekserew slide against the arm. Turning the jaekserew moves the arm in

Turn the traditional router table on its ear. Use it to cut tenons, raise panels, and edge-groove boards.

This project is an interesting—and space-saving— turn on the old horizontal router table idea. Mounting a router so die bit's axis is parallel to a work surface is the perfect setup lor any operation that, performed on an ordinary router table, would require you to balance the workpiece on edge:

•Cutting tenons

•Cutting wide rabbets

• Gnxiving the edges of straight, flat boards

• Raising panels with a vertical bit

• Routing architectural molding with tall face-molding bits

•Cutting dovetail pins for sliding dovetails

The horizontal-mounting idea isn't particularly new, of course. Router magicians have been cobbling them up for years. But when Phil Gehret and Rob Yoder. two of my woodworking colleagues, first mounted a router on the end of a table saw, the general reaction was CoooU What a smart idea.

Piggybacking a horizontal router setup on the table saw saves space in the shop.The router is mounted at the left end of the table saw. Usually, you keep the area around that end clear so you can crosscut a board that's longer than 2 feet. Keeping that area clear means it's dead space. This horizontal router table exploded view horizontal router table exploded view

Swing arm base ply

Plastic knobs

Horizontal Router Table

Spacer T-nuts

Slide bottom

Support

Swing arm top ply

Swing arm base ply

Support

Plastic knobs

Swing arm top ply

Spacer T-nuts

Slide bottom

ja im

ja im

Cutting List

Part Qty. Dimensions

Material

Swing arm base ply

3 '/2"x 18tt"x27"

Birch plywood

Swing arm top ply

1 y/xl8*5* X 27"

Birch plywood

Support

1 Va" X 27" X 33^"

Birch plywood

Spacer

1 116" X 214" X 27"

Hardwood

Slide top

1 \Wx 1WX4W

Hardwood

Slide bottom

1 3A" x 1 'A" x 13/4"

Hardwood

Shelf

1 }A"x WxlW*"

Plywood

such tiny gradations that you have to measure the cut to perceive the difference.

Equally important, the rig can be constructed and bolted to almost any floor-standing table saw in a matter of hours. The exotic hardware items arc as close as your telephone and mailbox.

This setup is not a substitute for a router table. Rather it's a complement to the router table. In tact, I've got a router hung under the right-hand extension wing of my table saw (see the photo on page 183). I use the router table extensively. But "workpiece maneuverability" is a key fork in my decision tree. If I have to balance a workpiece on edge to machine it on the router table. I'll switch to the horizontal setup st> I can lay it flat.

Hardware

2 pieces plastic laminate, each 20" x 28"

1 jackscrew. 3/g"-16; #AJS-500 from Reid Tool Supply Co. (800-25B-0421)

2 hex-head bolts with washers,'/«"-! 6 x 2"

3 fluted plastic knobs with HM6 x I W steel studs; #DK-6 from Reid Tool Supply Co.

1 fluted plastic knob with '/4M-20 threaded insert; #DK-59 from Reid Tool Supply Co.

2 carriage bolts. W x 1

6 drywall screws. 2" long 2 hex nuts, W

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Wood Working for Amateur Craftsman

Wood Working for Amateur Craftsman

THIS book is one of the series of Handbooks on industrial subjects being published by the Popular Mechanics Company. Like Popular Mechanics Magazine, and like the other books in this series, it is written so you can understand it. The purpose of Popular Mechanics Handbooks is to supply a growing demand for high-class, up-to-date and accurate text-books, suitable for home study as well as for class use, on all mechanical subjects. The textand illustrations, in each instance, have been prepared expressly for this series by well known experts, and revised by the editor of Popular Mechanics.

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