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How To Make A Router And Table Saw Combination

Both a table saw and a router table are important parts in the arsenal of any handyman or carpenter. Both of these tools are necessary to complete virtually any wood working job, however the problem is that both of these tools use up quite a lot of space. The way to save some space and still have both a table saw and a router table is to combine the 2 in to 1. You can do this by getting a table saw and modifying the extension wing by turning it into a table saw. The extension wing of the table saw can easily be turned into a router table extension. This extension will have 3 layers including the countertop made of laminate, a middle layer, and a bottom layer of plywood. There will also be a shop vacuum connected to it in order to get rid of excess sawdust. Follow the steps outlined below to create your own router extension for your table saw.

Making The Router Table Extension

The first step to doing this is to remove the extension wing from the saw table in order to replace it with the router table extension. After that you need to measure the length and width of the desired router table extension to get the proper dimensions. You can always extend the router table about 6 inches past the original dimensions of the saw table wing but no more. The first step to building your table router extension is to build the frame.

Photo Credit: http://www.woodworkersjournal.com

Building The Router Table Extension Frame

Using your previous measurements you should use 1 x 4 pieces of wood to build the basic rectangular frame. Make sure that this frame fits snugly in between the rails where the table saw wing extension used to be. Use 2 inch screws and wood glue to connect the corners of the frame. Also add a little ledge to the inside of the frame to support the top. This ledge should be the same thickness as the bottom layer of plywood.

After you have done this you should fit the frame into position on the extension wing. The top of the frame should sit about 5/16 of an inch lower than the saw surface. Mark the location of the bolt holes on your frame so you know where to attach it. The easiest way to do this is to put some black paint on the bolt holes of the extension wing and then to press the frame against the wholes; this will perfectly mark the holes on the frame. Drill out the holes on the frame and then use bolts to fasten the frame. You might not be able to use the original fasteners in which case you will need to buy the proper ones.​

Photo Credit: http://www.woodworkersjournal.com

Making The Bottom Layer Of The Router Table Extension

Measure the inside of the frame that you just built and then cut a ¾ inch piece of plywood to fit inside of the frame. The plywood should be supported by the ledges you inserted and the top of the plywood layer needs to be flush with the top of the frame. The plywood may cover up the bolt holes, in which case you need to mark the location on the plywood and use a router or another tool to cut out small pieces of the plywood so you can get to the bolt holes. Make sure your wrench can get to the bolt holes after removing pieces of plywood.

After this has been done you need to use the router to create a recess in the plywood layer that will become the internal dust conveying chamber; also drill a hole for the vacuum hose. The recess should be ½ inch deep and the vacuum hole should be 2 inches in diameter. You also need to drill a bit opening for the router bit. To do this you need to measure the diameter of the collet and then make the whole just slightly larger than the size of the collet.​

Combining The Middle And Top Layer

Cut the middle MDF layer about ½ wider and longer than the finished product will be to ensure that there is some overhang. Use contact cement to glue together the top laminate layer with the middle MDF layer. When the 2 layers are glued together use a hole saw to cut out the bit hole in the MDF/laminate layer. After this is done you need to glue these layers to the top plywood layer. Make sure that the bit holes match up evenly when doing this. Use contact cement to glue the layers together and use clamps to keep them in place while they dry. After this has been done you need to fit the layers into the frame and glue it in; use clamps to keep it together while it dries.

Photo Credit: http://www.woodworkersjournal.com

Completing The Table

Shave off the excess overhang in the top layers so that they are flush with the frame. The next step is to attach the router to the table by mounting it with screws. Make sure that the router is positioned over the center of the bit hole. After you have done this simply attach the newly built router table to the table saw using bolts and your table saw/router table combination has been built.

Photo Credit: http://www.woodworkersjournal.com

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