May be this is not enough for a professional carpenter, but as a woodworker with a garage shop, a router table to make my projects and to improve the possibilities of my small shop is something I long wished. Next is to make the fence, but I´ll show you that in another post.
To attach a plunge router to a table is not something very difficult. We remove the plastic base and we use it as a template to drill in the board the holes for the screws. We look for some long screws with the same diameter of the screws that we had to unscrew to remove the plastic base, we cut them to the length we need and we countersink the holes in the board.
Now we just have to make a hole in the middle so that the router bit can protrude the board and we screw the router to the board (you must be careful with the screws you use. The first screws I’ve used were too soft, and they broke when I was trying to tighten them, and a piece was trapped inside the hole in the router base).
Anyway, when making a do it yourself router table, the main problem is to find a way to regulate the high of the bit protruding the board, so first I made a router lift.
I was going to attach the router to a 1cm thick board, but because I want to make zero clearance inserts to use with the different diameter router bits that I have, and I also have to countersink the holes to the screws, I think the board between the router base and the screws head would be only a few millimetres thick. And the board could eventually break under the screws head. So I decided to use 16mm plywood. I bought some pre-cut pieces. I couldn’t afford the full plywood sheet but I found pre-cut pieces with the prefect dimensions I need to make my table.
I didn’t use any kind of jig to route the shape for the zero clearance inserts. It seems to be something very difficult to make if you are not skilled in doing it. But if you cut first the outline with a cutter and then we get close slowly to that cut with our router bit, we´ll see how the wood jump right in the cut, so we don´t route beyond the line. Then we just need some retouches with a chisel and some sanding to adjust the insert.
Those of you who attached this kind of router under a table board probably already know that one of the problems when making a homemade router table is that the collect doesn’t protrude the table board. And if the router bit shank isn’t long enough sometimes we cannot reach the high we need. After some check it happens that I will need a router collect extension, but with that collect extension it will be easier to change the router bits.