router table

Start by cutting out the plywood parts for the cabinet according to the dimensions in Fig. I. Notice that the horizontal panel in the middle and the bottom panel are dadoed into the cabinet sides. The two small top panels above the drawer spaces fit into rabbets cut in the top edge of the sides and the inside walls of the drawer spaces. Everything else is fastened with butt joints. Glue and nail the Vi-in. thick drawer runners in place on the sides of the drawer spaces. (The top-right drawer has a false front where the on/off switch will be mounted.) Nail a plywood divider panel between the two inner drawer sides.

Next, rout a ^-in. x f/4-in. deep rabbet around the inner perimeter of the back of the cabinet to hold the back panel. Cut a piece of Vi-in. plywood to fit in the rabbet (leaving the space behind the divider open). Make a face frame for the front of the cabinet by cutting 3/4-in. x 3/4-in. oak strips to size. Glue and nail them in place on the front edges of the cabinet parts. Make the bottom oak strip I 5A in. wide to cover part of the plinth. The oak strips are simply butted together. Chamfer the edges of the oak strips slightly with a chamfering router bit. Finally, cut out the pieces for the plinth and fasten them against the recessed bottom of the cabinet.

To make the top, cut two pieces of 3/4-in. AC plywood to size and glue them together to make the required 1 Win. thickness. (See Fig. 1.) Glue on the V*-in. x 1 '¿-in. oak edge banding and miter the joints at the comers. Cut a 1 '/4-in. radius on the edge banding at the comers. Now glue a piece of plastic laminate on the top surface and a piece of laminate backer board (plastic laminate without the colored top layer) on the bottom surface of the top. Finally, chamfer the top edge of the laminate and edge banding with a router bit.

To prepare for mounting the router in the top, lay out the location of the cutout in the top for the router base plate. Now rout a %-in. wide x 3/4- in. deep groove around the inside perimeter of the layout lines to begin forming the cutout exactly the same size as the base plate. (See photo.) The easiest way to rout this groove is to use a template sized from the base plate. A template-guide bushing installed on the router rides the template to guide the bit as it cuts the groove. After cutting the groove, remove the interior of the cutout by sawing completely through the top with a saber saw, leaving a 3/i-in. wide rabbet around the inside edge of the opening. This rabbet, which is really the bottom of the groove you cut. will hold the base plate. Screw the top to the cabinet with four 2-in. drvwall screws.

Mount the router on the center of the base plate. Orient the router in the top so its handles will clear the cutout. Also, make sure the router's clamping mechanism will be easv to reach. You mav need to cut notches in the rabbeted edge of the cutout to allow clearance for the router handles when lifting the router and base-plate assembly in and out of the top. (See Fig. 1.) We removed the router's original sub-base and used it as a pattern to mark the mounting-screw holes in the new plastic base plate. Drill and countersink the mounting holes, and mount the router on the base plate. If you're making your own base plate, you'll also need to cut a hole in the middle of the base plate for the router bit to project through.

The drawers are simply flat pieces of plywood drilled with holes for bit storage and fitted with a lipped birch-plywood front. To make the flat drawers, cut pieces of s/4-in. plywood to size as shown in Fig. 1. Drill a selection of 9/u-in. and I7A2-in. holes through the plywood for your '/»-in. and Vi-in, router-bit shanks. (Tip: Since you're drilling the holes through the drawer bottoms, you can stack two or three pieces together and drill them all at once.) Glue a piece of Vi-in. plywood on the bottom of each drawer to act as a stop for the bit shanks. Finally, cut out the drawer fronts, rabbet their backsides to form a lipped edge (see detail in Fig. 1). and fasten them to the drilled drawer pieces. Install the knobs. You can modify one or more drawers by installing sides so the drawers can hold router accessories. Paint the cabinet.

We provided an auxiliary on/off switch for the router

Shape the rectangular cutout in the top by routing a groove along a router template sized from the new plastic base plate.




Apply Vi-in. X I'Mn. oak edge h -»«aid iwiiajh.ii üimmair oanomg muí mi .orea corners.




oak face frame ViW.xViW




Apply plastic laminate top and bottom.

Notch for router handles If necessary.

Remove router sub-base before mounting router.

Leave iVw-ln. spaces between drawer runners.

Dr! holes for router-bit storage

Nai drawer ruiners to sides. iu/»i vt x 19V. n. 27/u it x 19s/. It 2u/u n x 19»/. «.

Mount duplex outlet In electrical box.

Mount switch h electrical box in right top drawer front.

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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