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Indoor Furniture
Dave Campbell
Editorial Content Chief, WOOD magazine
WOODStore.net
DOWNLOADABLE ONLINE WOODWORKING PLANS
®
http://www.woodonline.com
Router Table
and Organizer
Whether you keep it simple or dress it up, this project
will become your shop’s one-stop router headquarters.
W
hen your router accesso-
ries have scattered around
the shop like chips flung
from a panel-raising bit, corral them
in the drawers and cabinet of this
virtually indestructible, easy-to-make
router table. You’ll gain a rock-solid
worksurface, with quick router access
to adjust and change bits. Then see
page 11 for accessories to make a
great table even better.
B
Assembling the base in stages ensures that the shelf (B) mounts
square to the side. The unglued side (top A) helps you align and clamp
the subassembly.
Page 2 of 12
finish assembling the base
Now add two simple doors
A 1 Measure the height and width of the
bottom compartment, then cut two
doors (I) 1⁄8" shorter than the opening
and 3⁄16" narrower than half the width of
the opening [Drawing 1].
2
E D On each door (I), cut the finger pull
with a jigsaw and sand smooth. Rout
1⁄ 8" round-overs on the inside and out-
2"
1/16" spacer
3 Cut each front (J) 1⁄16" shorter than
the drawer opening width. On each
drawer front, jigsaw a finger pull and
sand it smooth. Rout 1⁄8" round-overs on
the inside and outside half-circle edges.
I
4 Rabbet both ends of each drawer
front (J) and dado each drawer side
(K) to accept the drawer back (L).
D
Resting the door (I) on risers lets you control hinge
placement on the case side (A). Center pilot holes in the
oblong hinge slots to fine-tune the door position later.
Page 3 of 12
P Q R
O
1 exploded view
U
P O
#8 x ¾" F.H.
#8 x 1½" F.H. wood screw angled into top 71⁄8" wood screw
G
D
A
D G
6¾" 143⁄8"
E C
E
Strike E C
plate E
121⁄8" 2" F
B
I 201⁄8" 34½"
6" 63⁄8"
R=1" Magnetic
catch ¾" dado 3⁄8" deep
157⁄8" A
B
19¾"
1⁄8" No-mortise
round-over wraparound hinge 25¼"
H
24½" 3"
20"
20" 19¾"
¾" rabbet ¾" rabbet
3⁄8" deep 3⁄8" deep
5"
Page 4 of 12
½" 3½"
¼" groove ½" dado
2 Drawer ¼" deep
57⁄16"
¼" deep
¼" from bottom edge
L
K 311⁄16"
43⁄16"
1⁄8" round-over
¼"
15¾"
57⁄16"
43⁄16" M K
J
R=1" 19½"
½" rabbet
½" deep
515⁄16"
¼" groove ¼" deep
¼" from bottom edge
3 router-table top
9 x 12" insert
2 DRA WER
1⁄8" chamfers
Filename: 192 RouterT
routed after O
R LeMoine/ K Boyle/ J
assembly
FILENAME:
Date: 3-09
192RtTble2_#100672364.ai RL 2-5
8 x 11" opening,
centered
Lorna J. RL 3-11
P
N
1½"
21½"
32"
P
Page 5 of 12
clamp on a frame for routing make plunge cuts in stages
Insert
MDF frame 3/8" spacer
N / O/ P
E F
N /O/ P
Center the router-table insert on the top assembly (N/O/P), then frame With 3⁄8"-thick spacers inside the MDF frame, rout clockwise through
it with MDF strips wide enough to accommodate your router base. the laminate and upper MDF tabletop (N) in 1⁄4"-deep passes.
N / O/ P
underside
G H
Cutout corner holes define where to saw away the lower top (N). The From the underside of the top assembly (N/O/P), ride the bottom-
frame corner holes remove stock the rabbeting bit can’t reach. bearing flush-trim bit against the inside edge routed earlier.
Page 6 of 12
Install a router base plate
1 Center the insert plate on the table- 4 Remove the MDF frame from the top
assembly (N/O/P), turn the top
until the dust port rests flat on the sup-
ports (S).
top, and frame it with MDF strips
clamped and double-faced-taped to the
tabletop [Photo E]. Remove the insert.
assembly upside down and draw lines
between the centers of the holes. Cut
out the opening with a jigsaw.
4 Bore a centered 21⁄2" hole in the fence
dust port (T). Glue and clamp the
port in place. Center a plastic dust port
Note: The router-table insert we used (see
Sources) has a 1⁄2"-wide rabbet around the 5 With a bottom-bearing flush-trim
bit, rout from the table underside to
[see Sources] on the fence dust port;
then drill and screw it in place.
underside edge. If your insert lacks this lip,
modify the spacer thickness and bushing
diameter to adjust the dimensions in the
clean up the opening [Photo H].
6
3⁄4"-wide spacers to the inside edge of the router-table top is crucial for smooth table Saw the fence clamps (U) to size, and
MDF frame using double-faced tape. routing. Remove most of the material for the bandsaw notches where shown.
Plunge-rout through the laminate and lip supporting the insert in one or two passes, Insert a carriage bolt through each
top layer of MDF, working clockwise but make the final pass a light, skimming clamp block and add the washer and
around the frame with the router bush- one to leave a smooth, uniform lip. knob.
ing against the spacers [Photo F].
Quick tip: Use multiple passes.
Plunge rout in 1⁄4"-deep passes to the maxi-
7 Test-fit the insert in the opening. If
the fit is too tight, lightly trim the
plate on a tablesaw. If the plate is too
7 Remove all the hardware, finish-
sand the parts to 180 grit and apply
a finish. (We used two coats of wipe-on
mum length of the bit to avoid overtaxing loose, glue narrow filler strips around polyurethane, sanding with 320 grit
both router and bit. Remove the 3⁄8"-thick the tabletop opening. between coats.)
spacers and the unglued upper layer of
the tabletop (N). 8 Rout a 1⁄8" chamfer on the top and
bottom edges of the trim (O, P); then 8 Mount the top assembly (N/O/P) to
the base. Then drill and screw the
3
Illustrations: Roxanne LeMoine; Lorna Johnson
Note: Our router-table insert has 1⁄4"-radius Cut the fence dust port (T) to size. Graphic design: Lorna Johnson
corners, so we used a 1⁄2"-diameter drill bit. Sand a 45° chamfer on one end of
If your insert corner radius exceeds 3⁄8", drill the port to fit against the fence base (R)
these holes before routing the top. [Photo J]. Then chamfer the top end
Q
Chamfer
R
I J
Rabbet clockwise between the drilled holes with a bearing-guided bit Chamfering the ends of the fence dust port (T) helps it form a tight
to create a lip that will accept the insert. seal against the fence front (Q) and base (R).
Page 7 of 12
27⁄8"
S S
27⁄8"
3⁄8" star knob
36"
3⁄8" hole 3⁄8" washer
Q
3¼"
3¾" 1"
2¾" 165⁄8"
S
S 1"
3⁄8" hole,
2½" hole, centered
7" 2" centered
T 1"
R 13⁄16" 2¼"
45⁄16" U
4¼" 3"
U 1⁄8" chamfer
1" 6¼"
4 FENCE Filename: 192 RouterTable XX 02-
w ed from back) 3⁄8" hole 1" R LeMoine/ K Boyle/ J Mertz 1-6
ILENAME: 192RtTble4_#100672366.ai
RL 2-5
Date: 3-09
U RL 3-11
orna J.
U 2¼"
2"
3" 13⁄16"
Page 8 of 12
U** fence clamps 11⁄2" 21⁄4" 3" BP 2
Tabletop
3
N** tabletop ⁄4" 211⁄2" 301⁄2" MDF 2
O tabletop end trim 3⁄4" 11⁄2" 211⁄2" P 2
3
P tabletop side trim ⁄4" 11⁄2" 32" P 2
Fence
3
Q fence front ⁄4" 33⁄4" 36" BP 1
3
R fence base ⁄4" 31⁄4" 36" BP 1
3
S fence supports ⁄4" 27⁄8" 27⁄8" BP 4
T fence dust port 1⁄4" 41⁄4" 45⁄16" MDF 1
Sources Page 9 of 12
Router-table insert. All-In-One Router Plate
Kit (9×12") no. 9338, $35, MLCS, 800-533-9298,
mlcswoodworking.com.
Cutting Diagram
J J S
R
Q H
U
A B C D
A B C D
¾ x 48 x 96" Plywood
M T M
M N
G G
M
M
F
M
E E
E E
¼ x 48 x 48" ¾ x 48 x 48"
Medium-density fiberboard Medium-density fiberboard
O P *L
*K *K *K *K
*K *K *K *K
¾ x 5½ x 96" Poplar (4 bd. ft.)
Page 10 of 12
Rev up your router table
Our editors choose “Let’s start with a must-have: a good fence. It’s essential for accuracy, dust collection, and
safety. I really like this Woodpeckers fence because, for $135, you get everything you need:
four accessories tall fence panels, T-slots, a dust port that actually fits my shop vacuum, leveling screws to
keep the fence square to the table, shims for offset jointing, and a see-through bit guard.”
that will dramatically
Kevin Boyle,
improve your table’s Senior Design Editor
performance. 32" LE Router Table Fence, #LEFNC616, $130;
Woodpeckers, 800-752-0725, woodpeck.com
Jeff Mertz,
Design Editor
Bob Hunter,
Tools & Techniques Editor
Safety Power Tool Switch, #20915, $30;
Rockler, 800-279-4441, rockler.com
Page 11 of 12
Elevation
The Perfect
tool
Router for
Table Mounting A good table-mounted router makes bit
changes hassle-free. An angled wrench
Is there such a thing? to hold the spindle sure helps.
We found three that fit the bill.
A
lthough you can mount nearly any handheld router
upside down in a router table, some are better suited
to this line of duty than others. For example, many
routers now sport built-in lift mechanisms that you crank to
adjust bit heights from above the table, as shown at right,
without removing the router or reaching below the table.
These routers typically require an extra hole in the insert
plate to operate the lift mechanism. But beware: With some
of these routers you still have to reach below the tabletop to
lock the collet, negating half the benefit of a lift.
If you already have a router you like and don’t want to
upgrade, you might be able to get the same convenience by You should also look for a router with variable speeds so
installing its motor in a router lift. These units come you can slow it down for large-diameter bits. Another
attached to insert plates with adjustment mechanisms built essential feature: electronic speed control, which maintains
in, as shown below. Keep in mind, though, that with prices rpms when the routing gets tough. A 3-hp motor really hogs
ranging from $175 to $450, a lift might cost more than a away material, but a midsize model (11⁄2 to 21⁄4 hp) will get
new router. Router lifts specify which router models will fit, you by if you taker lighter cuts.
and some require adapters. When mounting any router in a table, position it so the
variable-speed control will be easy to reach, because this
give your ordinary router a lift cannot be controlled from above. Add an auxiliary power
switch to avoid reaching under the table each time to power
the router. Also, be careful to mount the router so any
above-the-table adjustments won’t be covered by the fence
during operation, because you might need to tweak a bit’s
height with the fence in place.
Recommended routers
We’ve used a lot of routers over the years at WOOD®
magazine. These three rank among the best for
table routing:
Porter-Cable #892, 21⁄4 hp, 10,000–23,000 rpm, $190,
888-848-5175, deltaportercable.com.
■ The 892 features two power switches plus a speed dial marked in
rpms, and its lift mechanism works smoothly and accurately.
Triton #MOF001, 21⁄4 hp, 8,000–21,000 rpm, $220, 888-874-8661,
tritonwoodworking.com.
■ This easy-to-use router with built-in safety switch won’t
accidentally power up while you’re changing bits.
Freud #FT3000VCE, 3 hp, 8,000–21,000 rpm, $350,
800-334-4107, freudtools.com.
■ You won’t bog down this robust router, and the spindle locks
A router lift, shown out of the table, raises the router fully so you can from above the table for one-handed bit changes.
change bits above the table without angled wrenches.
Page 12 of 12
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