How to install your router in your router table.

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How to install a Base Plate in your Router Table
1/04

To mount my router in it's new home, I first had to determine exactly where it would fit. I wanted a sloping surface beneath the router to help clear the chips, and I have drawers below that sloping floor to consider. So I grabbed some scrap stock to reproduce the thickness of the table top, and then used a straight edge to make sure the top of the base was even with the top of the table saw, since the table saw and router table are on the same plane.

Here you can see the sloping floor and the router. I lowered the router all the way and then slid it up to the floor leaving about a 1/4" gap. Then I measured the distance between the base and the end of the table that bolts to the table saw.

Now you'll need to chuck a 1/2" straight cutting bit into your router, then measure the distance from the cutting edge to the edge of the router's base. In my case this was 2-3/4"

Now you can make your jig. This jig makes the groove that the lip of the router base sits on. The center part is cut out later. When making your jig, take your base plate that you want to install in your router table, and add that dimension you took earlier on all sides. When the router runs around the inside of the jig, it removes stock that will be under the edge of this plate.

Double check all your measurments, then check them again!

Now set your router to the depth of lip on your plate. I set mine to 1/4". I also ran a few layers of masking tape around the base of my router. I did this for insurance reasons. If I make the jig a shade too big, my plate will be sloppy and loose. Not good. I can always remove a layer of the tape and make the opening a shade bigger later.
The pic at left shows the masking tape, besure to remove what you don't need, you don't want it finding it's way under your router while you makin the hole!

Ok, now take that jig, center it and clamp it down to your router table. Nows the time to make sure the jigs is positioned perfectly, once you start cutting, there's no turning back!

Just like wrapping my router's base in masking tape, I also put some masking tape on the tables surface for the same reason. If your cut isn't deep enough, you can always remove some tape and cut again.

Ok, now grab that router, and plunge it into your router table....move in a slow but steady pace in a clockwise direction. Don't go too slow or you'll burn your workpiece and overheat your bit. Don't go too fast or you'll chip the laminate.

When your done, don't remove the jig!!!

Next I took my circular saw and placed it where I wanted to cut for the hole. Measure between the saw's shoe and your jig, and cut some stock that size. This will guide the circular saw for each cut. Yes you'll need a longer scrap and a shorter scrap, one for the long cuts and one for the shorter one. Be careful, don.t mess up the corners.

When your done, don't remove the jig!!!

Finish off the corners with a jigsaw or hand saw and support (not with your hand) the piece so it doesn't break off and chip the laminate.

When your done, don't remove the jig!!!

Ok, now grab that base plate and see if it fits.....mine didn't. I had a bump in one of the corners, probably sawdust got between the jig and my router. Easily fixed, since the jig is still clamped to the table.
I also had to remove some of the tape I wrapped around my router and retrim two sides. I left the tape I had put on the table surface, the plate was perfectly flush. I'm glad I put tape on the table top, my routers base plate would have been low.

This is a pic of mounting the router table to the cabinet and table saw. Again I use a straight edge to insure everythings on the same plane.

Nearly complete! I just need a fence. For now I'll just use my old one that clamps to my tablesaw's fence.

Back to making that mobile cutting/routing cabinet.

Add Fence accessories and a miter slot to your router table

Here is a good selection of routers and some info on each oneA great selection of routers and trim routers.
I have the Green Shaded routers and I'm quite pleased with them!

New! Porter-Cable 893PK Router Package	Porter-Cable 891 Grip Vac Router Package	Porter-Cable 894PK with Plunge Base, Fixed Base and VacGrip handle	Porter-Cable 895PK with Fixed Base, Plunge Base and Micro Height Adjuster	Proxxon Micro Shaper
New! Porter-Cable 892 Router Package	Porter Cable 690LR Router	Porter Cable 3-1/4 HP Five-Speed Plunge Router, Model #7539	Porter Cable 1-3/4 HP D-Handle Router, Model #691	Porter Cable Cordless Router Model 9290
Porter Cable Trim Router	Betterley Coving System	Betterley Dustless Underscribe Router	Betterley Flush Trimmers	Bosch 2-1/4 HP VS Router.

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