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Router table insert

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Anonymous

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Hi all

Been asked half a dozen times lately about my home-made router table insert

Well, here it is. 6mm aluminium sheet with a big hole in; with a shoulder cut into it. One could easily attach two 4mm sheets together with large hole in top one and smaller hole in bottom to give the same shoulder.
I have drilled 6 levelling holes around the edge and have mounted six 4mm bolts under it with lock nuts. I place an allen key through the holes to level it off and lock the nuts from underneath. 4 fixing screws in corners.

Inserts were a single piece turned on a lathe to fit and then chopped into 3mm thick pieces. I cut various sized holes (my range of holesaw sizes :wink: ) in them to accomodate the various router bits I am likely to use.

I recently drilled a few rows of 4mm holes in the top and countersunk them slightly - this helps loads with dust collection on the table as the inseret plate is mounted above a sealed plenum chamber (Norm design) which draws air down through all of them + the tool hole. Especially good when cutting slots in wood as all the waste gets pulled down from the groove :)


There are several holes around the centre of the plate (need to get some of that metal filler stuff) as I have had 3 differnet routers mounted in it and all of them had different fixing centres :roll:

Well, there it is. Works pretty well and is flat and stable and cheap :wink:


 

dedee

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Tony,
your insert plate appears to be proud of the surrounding table or is this an illusion?

Andy
 

Neil

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Absolutely fantastic, Tony :D - I would love one of these for my table! I think I could cope with making the insert from two pieces of 4mm sheet as you suggest, but I wouldn't have a hope of making the inserts :oops: - Do you think I could make them using the same 4mm sheet and a circle-cutting jig on the router? :? I haven't done any routing of aluminium and the thought of it makes me a little nervous...

Extraction holes are a great idea too 8)

Neil
 

Alf

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Up the proverbial creek
So when d'you start taking orders then? :D Free shades included with every one of course... 8) :wink:

Cheers, Alf
 

Gill

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Alf's right - you could market that sort of quality insert.

Gill
 

Chris Knight

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Aluminium can be routed very easily and cut nicely on a tablesaw. I have done both - occasionally by accident and sometimes by design. I would have thought that borrowing Tony's design, everything could be made from suitable plate using these tools? It might be worthwhile to get the plate anodised if possible.
 
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Anonymous

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Chris

Interested in you comment about routing aluminium. Does it work well with conventional TC router cutters? I would have thought there may be a problem with build-up on the insert.

Re inserts, you can make similar inserts in polycarbonate or phenolic. That's how I made mine, following the method in Bill Hylton's book Router Magic. The big advantage in my opinion is that you can see through them!
 
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Anonymous

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dedee":2676vltr said:
Tony,
your insert plate appears to be proud of the surrounding table or is this an illusion?

Andy
An illusion. It is absolutely lined up flush using the adjustment screws.

Neil

I think the inserts could be made using the router and a circle jig. I have machined a lot of aluminium using a router on minimum speed. I tend to use the freebie bits I got with my cheaper router and they do a fine job :wink:
I think a very thin bit would be best, maybe 5 mm or so straight cut
Be interested to find out how it works for you
 
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Anonymous

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GillD":y2tpok45 said:
Alf's right - you could market that sort of quality insert.

Gill
Making one's OK but I never enjoy making a second of anything whetehr elcetroncem netal or wood :(

I do have engineering drawings for mine and if anyone wants a copy just pm with an email address - I might be able to make them into a PDF
 
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Anonymous

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tycho14":32h86xj8 said:
Chris

Interested in you comment about routing aluminium. Does it work well with conventional TC router cutters? I would have thought there may be a problem with build-up on the insert.

Re inserts, you can make similar inserts in polycarbonate or phenolic. That's how I made mine, following the method in Bill Hylton's book Router Magic. The big advantage in my opinion is that you can see through them!
Hi Tycho

I have routed loads of aluminium and never had build up problems using a light cut and slow speed
 

Chris Knight

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Tycho,

I have used ordinary bits as per Tony's comment but you can get bits for the aluminium window industry - I think Trend do these - and I guess these may be better if one were to do very much.
 

Bean

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I thought it was such a good idea that mine is on the way, I should take delivery of the ali tomorrow, then with a bit of fettling and a bit of twiddling we will be away 8)

Bean
 

crazylilting

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Dredged from the last page!!!

Wow this is nice, I haven't been here long so I thought i'd check out some of the old threads, this one is worth bumping for others who haven't seen it.
 

Gill

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Well done for dragging it up again, CL.

Now, Tony... so much time has passed that making another wouldn't really be like making a second. I'm ever hopeful :D .
 

Dibs-h

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Gill":3fc1nubo said:
Well done for dragging it up again, CL.

Now, Tony... so much time has passed that making another wouldn't really be like making a second. I'm ever hopeful :D .
There's a firm at the bottom of my road, who have an EDM machine (and all the normal machining equipment manual & CNC) and could easily produce the circular inserts (and\or the whole table inserts) and don't charge the earth. Would anyone be interested - sort of a zero profit Group Buy thing? Worth exploring? Assuming Tony approved.
 

Gill

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Add me to the list too, please :) .

Oh heck, I've just realised - that means I'll have to build a new router table. Proper woodwork as opposed to the sort of fripperies I normally indulge in 8-[ :) .
 

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