Router Table On Table Saw Extension – Maximize Your Workshop Space

Every woodworker knows the struggle: workshop space is always at a premium, and the desire for more tools constantly battles against the reality of limited square footage. You dream of clean, precise dados, decorative edges, and perfectly fitting joinery, but a dedicated router table feels like another bulky item you just can’t squeeze in.

What if I told you there’s a simple, incredibly effective way to gain all the benefits of a full-sized router table without sacrificing precious shop real estate? Imagine transforming your trusty table saw into a dual-purpose powerhouse, ready for both ripping lumber and routing intricate profiles with a quick setup.

In this comprehensive guide, we’ll dive deep into how to implement a router table on table saw extension, covering everything from the planning stages to installation, optimal use, and essential safety practices. By the end, you’ll have all the knowledge and confidence to upgrade your workshop, streamline your workflow, and tackle more ambitious projects than ever before.

Why Combine Your Tools? The Benefits of a Router Table on Table Saw Extension

For many woodworkers, the idea of adding a router table to their existing table saw extension isn’t just a convenience; it’s a game-changer. This clever integration offers a multitude of advantages that can significantly improve your woodworking experience and project outcomes.

Let’s explore the key benefits of router table on table saw extension setups.

Space-Saving Efficiency

The most immediate and obvious benefit is space. A dedicated router table, even a small one, requires floor space. By utilizing your table saw’s extension wing, you effectively get two powerful tools in the footprint of one.

This is invaluable for smaller workshops, garages, or even just keeping your shop less cluttered and easier to navigate.

Enhanced Workflow and Versatility

Think about your typical project. You often need to cut parts on the table saw and then route them. With an integrated setup, you can perform both operations at the same workstation, reducing the need to move material or switch between different machines.

This creates a more fluid and efficient workflow, especially when working on repetitive tasks like routing multiple identical pieces.

Utilizing Existing Infrastructure

Your table saw already has a sturdy, flat surface and often a robust fence system. By adding a router, you leverage this existing infrastructure.

Many setups allow you to use your table saw’s rip fence as the router fence, which means less setup time and greater accuracy, as it’s already aligned with your work surface.

Cost-Effectiveness

While you still need to purchase a router and a router plate, you save on the cost of a dedicated router table cabinet or stand. For hobbyists and DIY builders, this can be a significant saving, allowing you to invest more in quality bits or other essential tools.

Planning Your Router Table on Table Saw Extension: What You Need to Know

Before you jump into installation, a little planning goes a long way. This section serves as your comprehensive router table on table saw extension guide, helping you make informed decisions about components and setup.

Careful consideration now will save you headaches later.

Choosing the Right Router

Not all routers are created equal, especially when it comes to table mounting. Look for a router with these features:

• Variable Speed: Essential for different bit sizes and wood types.
• Soft Start: Reduces torque on startup, making it easier to control.
• Above-Table Bit Adjustment: A huge convenience, allowing you to change bits and adjust height without reaching under the table.
• Power: A 2-1/4 HP to 3-1/4 HP fixed-base router is generally ideal for table use.

Plunge routers can work, but a fixed-base router is often preferred for dedicated table use due to its simpler mounting and adjustment mechanisms.

Selecting a Router Plate

The router plate is the heart of your integrated setup. It’s the sturdy platform that holds your router and sits flush with your table saw extension.

• Material: Phenolic resin or aluminum are common. Phenolic is lighter and quieter, while aluminum is incredibly durable.
• Size: Ensure it fits the opening you’ll create in your table saw extension.
• Pre-drilled vs. Blank: Pre-drilled plates are convenient if they match your router model. Blank plates offer more flexibility but require precise drilling.
• Leveling Screws: These are crucial for ensuring the plate sits perfectly flush with your table surface, preventing snags.

Considerations for Your Table Saw Extension

Most table saws have a cast iron or stamped steel extension wing. You’ll be cutting an opening in this wing to accommodate the router plate.

• Material Thickness: Cast iron is thicker and more stable but harder to cut. Stamped steel is easier to work with.
• Support: Ensure the extension is adequately supported. If it’s a lighter gauge steel, you might need to reinforce it to prevent sag, especially with a heavy router mounted underneath.
• Dust Collection: Plan for dust collection from the start. A router generates a lot of fine dust, and effective extraction is vital for safety and cleanliness.

Designing Your Router Fence (or Using Your Table Saw Fence)

You have two main options for a router fence:

1. Dedicated Router Fence: This offers the most flexibility, often including adjustable sub-fences, dust ports, and sometimes even a bit guard. You can build one yourself or buy an aftermarket model.
2. Table Saw Rip Fence: Many woodworkers simply use their table saw’s rip fence. You’ll need to add sacrificial wooden faces to it to create a zero-clearance opening for the router bit. This is a simple and effective solution, though it lacks some of the advanced features of a dedicated router fence.

For a beginner, using the table saw fence with sacrificial faces is an excellent starting point.

How to Router Table on Table Saw Extension: Step-by-Step Installation

Ready to get your hands dirty? This section walks you through the practical steps of setting up your router table on table saw extension. Remember to take your time and measure twice, cut once!

Safety glasses and hearing protection are a must for this process.

Step 1: Mark and Cut the Opening

First, carefully position your router plate on the table saw extension wing where you want it to be. Typically, this is towards the right side, away from the blade.

• Trace the Plate: Use a pencil to trace the exact outline of your router plate onto the extension wing.
• Drill Pilot Holes: Drill a few pilot holes just inside your traced line. These will allow you to insert your jigsaw blade.
• Cut the Opening: Using a jigsaw with a metal-cutting blade (if your extension is steel) or a diamond blade (if cast iron, though this is much harder), carefully cut out the opening. Stay just inside your pencil line to ensure a snug fit.
• File and Deburr: Smooth any rough edges with a file.

For cast iron, consider using a router with a carbide bit and a template, or even having a machine shop do the cut if you’re not comfortable.

Step 2: Mount the Router Plate

Test fit your router plate into the opening. It should sit flush or slightly below the surface. If it’s too tight, carefully file the edges of the opening.

• Drill Mounting Holes: Mark and drill holes for the plate’s mounting screws. Countersink these holes so the screw heads sit flush or below the table surface.
• Install Leveling Screws: Most router plates come with leveling screws. Install these around the perimeter of the opening. These screws allow you to fine-tune the plate’s height to be perfectly flush with the table saw surface.
• Secure the Plate: Mount the plate using flat-head machine screws. Adjust the leveling screws until the plate is perfectly flush. Use a straightedge to check for any high or low spots.

Step 3: Attach the Router

Now it’s time to connect your router to the plate.

• Position Router: Place your router upside down on a workbench. Align the router plate on top of its base.
• Mark and Drill: Mark the screw holes from the router’s base onto the router plate (if it’s a blank plate). Drill and tap these holes, or use appropriate machine screws and nuts to secure the router to the plate.
• Install into Table: Carefully lift the router (now attached to the plate) and lower it into the opening in your table saw extension.

Ensure the router’s power switch is easily accessible, or consider adding an external safety switch.

Step 4: Set Up Your Fence

If you’re using your table saw’s rip fence:

• Create Sacrificial Fences: Cut two pieces of straight, flat plywood or MDF. Attach them to your rip fence using screws or clamps.
• Set Zero Clearance: With the router bit installed and the router turned off, position the fence so the bit passes through the gap between the two sacrificial pieces. Turn on the router and slowly move the fence over the spinning bit to create a perfect zero-clearance opening.

If using a dedicated router fence, follow its specific mounting instructions.

Mastering Your Router Table on Table Saw Extension: Tips for Optimal Performance

Once your setup is complete, it’s time to learn how to get the most out of your integrated router table. These router table on table saw extension tips will help you achieve clean, accurate results.

Practice with scrap wood before working on your project pieces.

Proper Bit Selection and Speed

The right router bit for the job is crucial. Match the bit profile to your desired cut, and always ensure it’s sharp.

• Bit Size and Speed: Larger diameter bits require slower router speeds to prevent overheating and burning. Smaller bits can run faster. Consult your router’s manual or a bit manufacturer’s guide for recommended RPMs.
• Climb vs. Conventional Cut: For most routing operations, you’ll use a conventional cut (feeding the wood against the rotation of the bit). A climb cut (feeding with the rotation) is sometimes used for very light passes to reduce tear-out, but it requires extreme caution as the router can grab the workpiece.

Feed Direction and Rate

Always feed your workpiece against the rotation of the router bit. This provides control and prevents the router from grabbing the wood and pulling it through too quickly.

• Steady Feed: Maintain a consistent, steady feed rate. Too slow, and you risk burning the wood. Too fast, and you can get tear-out or stress the router.
• Multiple Passes: For deep or wide cuts, always take multiple shallow passes. This reduces strain on the router and bit, provides a cleaner cut, and is much safer.

Using Featherboards and Push Blocks

These accessories are your best friends for control and safety.

• Featherboards: Clamp featherboards to your table or fence to hold the workpiece firmly against the fence and table. This prevents the wood from lifting or drifting, ensuring consistent cuts.
• Push Blocks/Sticks: Always use push blocks or push sticks to keep your hands away from the spinning bit, especially when routing small pieces.

Dust Collection is Key

Routers generate a lot of fine dust. A good dust collection system is essential for both your health and keeping your workshop clean.

• Port Integration: If your fence has a dust port, connect it to your shop vacuum or dust collector.
• Under-Table Collection: Consider building a simple enclosure under the router plate with a dust port to capture dust from below.

Common Problems with Router Table on Table Saw Extension and How to Solve Them

Even with careful setup, you might encounter a few hiccups. Knowing how to troubleshoot these common problems with router table on table saw extension setups will save you frustration.

A little patience and adjustment often resolve most issues.

Problem 1: Router Plate Not Flush with Table

If your router plate is sitting too high or too low, your workpiece can snag, leading to inconsistent cuts or even kickback.

• Solution: Use the leveling screws around the perimeter of the router plate. Turn them clockwise to raise the plate or counter-clockwise to lower it. Use a straightedge to check for flushness from multiple angles. Repeat until perfectly level.

Problem 2: Burning on the Workpiece

Burnt edges usually indicate friction, which can be caused by several factors.

• Solution:
  • Dull Bit: Replace or sharpen your router bit.
  • Too Slow Feed Rate: Increase your feed rate slightly.
  • Too Fast Router Speed: Reduce the router’s RPM, especially for larger bits or dense woods.
  • Too Deep Cut: Take shallower passes.
  • Resin Buildup: Clean your bit with a specialized bit cleaner to remove pitch and resin.

Problem 3: Tear-Out or Chipping

This often happens at the exit point of a cut, especially on cross-grain routing.

• Solution:
  • Backer Board: Use a sacrificial backer board behind your workpiece to support the wood fibers as the bit exits.
  • Sharp Bit: Ensure your bit is sharp.
  • Shallow Passes: Take very shallow final passes.
  • Climb Cut (with caution): For a very light final pass, a climb cut can sometimes reduce tear-out, but only attempt this with extreme care and a very light touch.

Problem 4: Excessive Vibration

Vibration can lead to poor cut quality and be unsettling to work with.

• Solution:
  • Secure Mounting: Ensure your router is securely mounted to the plate and the plate is tightly fastened to the table.
  • Router Condition: Check your router for any loose parts or worn bearings.
  • Bit Quality: Use high-quality, balanced router bits. Cheap bits can be unbalanced and cause vibration.
  • Table Stability: Ensure your table saw extension is stable and well-supported. Add additional bracing if necessary.

Safety First: Router Table on Table Saw Extension Best Practices

Working with power tools always demands respect, and a router table is no exception. Incorporating a router into your table saw means you’re operating two powerful machines in close proximity. Adhering to these router table on table saw extension best practices is paramount for your safety.

Never rush or become complacent when routing.

Always Wear Personal Protective Equipment (PPE)

• Eye Protection: Safety glasses or a face shield are non-negotiable.
• Hearing Protection: Routers are loud. Earmuffs or earplugs are essential.
• Dust Mask: Fine wood dust can cause respiratory issues. Wear a good quality dust mask, even with dust collection.

Unplug Before Adjusting

Before changing bits, adjusting the fence, or making any adjustments to the router or workpiece, always unplug the router.

This prevents accidental startups and serious injuries.

Use Push Sticks and Featherboards

As mentioned before, these are crucial safety accessories. They keep your hands away from the spinning bit and provide better control over the workpiece.

Never route a piece of wood that is too small to safely handle with push sticks.

Understand Bit Direction and Feed Direction

Always feed the workpiece against the rotation of the router bit. This provides control and reduces the risk of kickback.

The bit rotates clockwise when viewed from above; feed from right to left for edge routing.

Keep Your Work Area Clean and Clear

A cluttered workspace is a dangerous workspace. Ensure your table saw surface is clear of debris, tools, and cutoffs.

Good dust collection also contributes to a safer environment by improving visibility and reducing fire hazards.

Secure the Workpiece

Use featherboards, clamps, or your fence to keep the workpiece firmly against the table and fence throughout the entire cut.

Never freehand a cut on a router table unless you are using a specific jig designed for that purpose.

Maintenance and Care for Your Router Table on Table Saw Extension

Just like any tool, your integrated router table needs regular care to perform its best and last for years. Following a simple router table on table saw extension care guide will ensure longevity and consistent results.

Proper maintenance also contributes to a safer workshop.

Regular Cleaning

• Router Bits: Clean router bits after each use to remove pitch and resin buildup. This prevents burning and keeps them sharp. Use a specialized bit cleaner and a brass brush.
• Router Plate: Wipe down the router plate and table saw extension surface to remove dust and debris. A clean surface ensures smooth workpiece travel.
• Router Motor: Periodically blow out the router’s motor vents with compressed air to prevent dust buildup, which can cause overheating.

Lubrication and Inspection

• Router Collet: Inspect the collet regularly for wear. A worn collet can lead to bit runout and unsafe operation. Keep it clean.
• Table Surface: Apply a paste wax or a specialized table saw lubricant to your table saw extension surface (and the router plate) to reduce friction and prevent rust. This is especially important for cast iron.
• Fasteners: Periodically check all screws and bolts – on the router, the plate, and your fence – to ensure they are tight. Vibration can loosen them over time.

Sustainable and Eco-Friendly Practices

As woodworkers, we have a role in promoting sustainability. Here are a few thoughts for your integrated router setup:

• Bit Sharpening: Instead of immediately replacing dull bits, explore services that can professionally sharpen carbide router bits. This extends their life and reduces waste.
• Dust Collection: Invest in efficient dust collection. Not only is it good for your health, but it also allows for proper disposal or even composting of wood dust (check local regulations for treated wood dust).
• Material Choice: When building jigs or sacrificial fences, opt for sustainable materials like FSC-certified plywood or reclaimed wood when possible.
• Tool Longevity: Proper care and maintenance of your router and table saw ensures they last longer, reducing the need for premature replacement and minimizing environmental impact.

Frequently Asked Questions About Router Table on Table Saw Extension

Can I use any router with my table saw extension?

While technically you can mount most fixed-base routers, it’s best to choose one with variable speed, a soft start, and ideally, above-table bit adjustment features. A 2-1/4 to 3-1/4 HP router is generally recommended for adequate power.

Is it safe to have a router table so close to the table saw blade?

Yes, provided you follow proper safety protocols. The router is typically mounted on the extension wing away from the blade. Always unplug the router when not in use, and ensure the table saw blade is lowered or covered when routing. Never operate both tools simultaneously.

Do I need a special fence for the router table on my table saw?

You have options. You can use your table saw’s rip fence by attaching sacrificial wooden faces to it to create a zero-clearance opening for the router bit. Alternatively, you can build or purchase a dedicated router fence that offers more features like dust collection and adjustable sub-fences.

How do I prevent dust buildup when routing on my table saw extension?

Effective dust collection is crucial. If your router fence has a dust port, connect it to a shop vacuum or dust collector. You can also build a simple enclosed cabinet under the router plate with its own dust port to capture dust from below the table. Always wear a dust mask.

Can I route large panels on this integrated setup?

Yes, one of the advantages of this setup is the large support surface provided by the table saw’s main table and extension. This makes it ideal for routing larger panels or longer workpieces, offering stability that smaller, dedicated router tables might lack.

Transform Your Workshop Today!

Integrating a router table on table saw extension is a brilliant move for any woodworker looking to maximize their shop’s potential without expanding its footprint. You’ve now got a comprehensive guide, packed with actionable advice, from planning your setup to mastering its use and keeping it in top shape.

Remember, the core principles of woodworking—precision, patience, and paramount safety—apply more than ever when combining tools. Take your time with the installation, practice on scrap material, and always prioritize your well-being with proper PPE.

This upgrade will not only save you space and money but also unlock a new level of versatility in your projects, allowing you to create more intricate joinery and beautiful profiles. So, grab your tools, get planning, and get ready to elevate your craft. Stay safe and happy routing!