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A router table was on my “to-do” list for quite some time. I initially figured I would use the New Yankee Workshop style router table. In fact, I purchased the “measured drawerings” for Norm’s deluxe router station… however since then I added the flip top cabinet, bought a drum sander, got a bigger bandsaw, a cabinet saw, and started a workbench project. To save shop floor space, then, the router was going to have to go in the TS extension table. So I settled on a “hybrid” style: using NYW-style cabinet construction, but putting it in the extension table instead of a free-standing router table.

The only potential problem with putting this in the TS extension table is that it’s a few inches lower than I think most people build their router tables. This is a fine height for me, but for someone taller it might be too low.

Making the top

When I bought my Jet cabinet saw the extension table was not exactly flat - about 1/16″ dip in the center lengthwise. I didn’t think that would be good enough for a router table, so I decided to just make a new one! I used a torsion box design, using all 3/4″ mdf, biscuits and glue (no metal fasteners). The cross members are all half-lapped.

Believe me… that sucker is FLAT! Anyway, I laminated that with some white formica, and it turned out pretty nice, if I may say so myself.

Router lift cutout

Once I had the lamination done, I cut a hole in the top for the lift. This series of pics shows how I set up for that cut…

I knew where I wanted the router to go before I made the table… the supports under the top are all positioned to allow room for the router lift. I decided to put the router in the left end of the extension table (near the saw), instead of out at the end like I have seen some people do. It’s not really feasible for me to have the router on the end of the table, since my saw has to go all the way up against the wall on the right side.

I figure doing it this way will give me a LOT more work surface support. If I’m using a bearing bit and routing without the fence, I can stand in front just like any other router table. If I’m using the fence, I’ll be standing just a few inches to the right of where I stand when using the TS. This just seems like the most logical place to put the router, IMHO.

Next: Making the cabinet…

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