This is a continuation of my other table saw enhancements, Attaching a Sliding Crosscut Table Without Cutting Down the Rails and Attaching an Extra Cast-Iron Extension Wing.The additional cast iron wing that I attached to my table saw moved the wooden extension table another 10″ past the end of my rails. This allows me to relocate my router table to the far-right edge of the table saw without having to cut notches in my front and rear rails to accommodate the miter slot.
Converting the extension table into a router table.
I had to remove my fence in order to attach the additional cast iron wing. I didn’t want to put my fence back on yet but I realized that I needed to so I can cut a dado in the wooden extension table for the miter slot. This is the same extension table that I had previously removed. I temporarily reattached the front rail and did a quick fence alignment so my cut would be parallel with the edge of the table. This led to a slight problem as you’ll soon see.
I wanted to make sure I didn’t accidentally cut through any screws so I removed the legs for the table.I figured that I would make the miter track 6″ from the edge of the table. This would ensure that I didn’t hit any screws while cutting the dado. I wasn’t worried about hitting a screw and activating the brake in the SawStop since a screw by itself is too small to activate the safety system. I mainly didn’t want to mess up the carbides on my dado stack. I positioned the fence at the 6″ mark.
I applied some blue painters tape to help prevent chipping and scratching the laminate on the edges of the dado. In keeping with tradition, I miscalculated where I should put the tape. You’ll see what I mean in a second.
I clamped some scrap wood on the side of the table to help prevent tear-out. I made sure the clamps were positioned where they wouldn’t get hit by the blades.
I lowered the dado stack so it would make a scoring cut first. This is another step that can really help prevent the edge of the laminate from chipping.
I made my first pass. As you can see, the blue tape wasn’t positioned correctly so my first cut didn’t have tape on each edge. As it turns out this wasn’t a big deal. The laminate that SawStop recently switched to for use on their extension tables is some high-quality stuff and didn’t tear out at all. I didn’t have similar luck with the laminate for their older extension tables.
Here you’ll see one of the areas where I screwed up. Remember when I said I did a “quick fence alignment”? Well, I should have taken my time. If I had, I would have noticed that in aligning my fence I also slightly loosened the clamping pressure of the fence on the front tube. This caused my fence to slide a little bit as I was cutting and caused a slight unevenness in the dado.
I reattached the legs and temporarily clamped the extension table to the rails and the right wing, making sure it was flush. Then I drilled new holes through the sides of the wooden extension table for the bolts to attach it to the rails.
I laid the pattern on the tabletop in the spot where I am going to remove the material. Absolute precision is not critical at this point. I used a few pieces of painters tape to mark the inner edges of the opening.
I used a red Sharpie to trace the opening on the blue painters tape.
I’m using a jigsaw to remove the bulk of the material, roughly cutting it out about 1/4″ inside the lines.
…then used a try square to make sure the template was square with the table.
I outfitted my trim router with a 1/2″ pattern bit.
It was throwing up quite a bit of dust so I set up a dust collection hood to grab most of it out of the air.
I removed the support bars so I would have room for the Kreg PRS3040 Precision Router Table Insert Plate Levelers which installed easily from underneath the table.
The next step was to start hooking things up. I installed a 4-outlet electrical box that was wired to a motor power switch.
I can use the table saw fence with the router table. This photo shows how close I can get it to the router bit. I will be making an auxilary router table fence with built-in dust collection that I can attach to my table saw fence, but that’s a project for another day.
That’s it! Up next is an enclosure for the router and maybe some drawers for storing router bits. For now, I’ve got some other projects that require my attention.If any of this has been helpful to you, or if you have any suggestions or questions, please take a minute to post a comment below. I’d especially like to hear any suggestions for projects that you’d like to see me tackle.