Table Saw With Router Mount – Maximize Your Workshop Space

Every woodworker, from the weekend hobbyist to the aspiring cabinetmaker, understands the constant struggle: workshop space. It’s a precious commodity, often dictating what tools you can own and what projects you can tackle. We’ve all wished for a way to get more functionality out of our existing equipment.

That’s where the ingenious solution of a table saw with router mount comes into play. Imagine transforming your powerful table saw into a precision routing station, all without sacrificing an inch of extra floor space. This isn’t just a clever hack; it’s a game-changer for efficiency and versatility.

In this comprehensive guide, we’re going to dive deep into everything you need to know about integrating a router with your table saw. We’ll show you how to set it up safely and effectively, unlock its full potential for various projects, and troubleshoot common challenges. By the end, you’ll be equipped with the knowledge to make your workshop work smarter, not harder, and elevate the quality of your woodworking.

The Power of Combination: Why a Table Saw with Router Mount is a Game Changer

For many woodworkers, a dedicated router table is a dream, but space and budget often put it out of reach. That’s why incorporating a router into your existing table saw setup is such a brilliant idea. It’s a smart way to get the best of both worlds.

Unlocking New Project Possibilities

A router mount on your table saw opens up a world of new joinery and decorative possibilities. You can create precise dados for shelves, rabbets for back panels, and intricate profiles for molding or furniture edges. The rigidity of your table saw’s fence provides unmatched accuracy.

The Benefits of Table Saw with Router Mount

Let’s talk about the specific advantages this integrated system offers:

• Space Saving: This is arguably the biggest benefit. You eliminate the need for a separate, bulky router table. Your workshop stays more organized and less cluttered.
• Cost-Effective: Investing in a router plate or extension wing is often far less expensive than buying a standalone router table, especially for quality models.
• Enhanced Precision: Your table saw’s robust fence system is designed for straight, accurate cuts. Using it as a router fence provides exceptional control and repeatability for routing operations.
• Increased Versatility: Suddenly, your table saw isn’t just for ripping and cross-cutting. It becomes a multi-functional workstation capable of a wider array of woodworking tasks.
• Seamless Workflow: Transitioning between sawing and routing tasks can be quicker and more fluid when both tools are integrated into a single station.

This combination truly elevates your workshop’s capabilities, allowing you to tackle more complex projects with greater confidence.

Setting Up Your Table Saw with Router Mount: A Step-by-Step Guide

Getting your router properly integrated with your table saw is a straightforward process, but it requires attention to detail. This section provides a practical “how to table saw with router mount” guide, ensuring a safe and effective setup.

Choosing the Right Router Mount System

There are generally two main types of router mount systems for table saws:

1. Router Plate Insert: This is the most common method. A heavy-duty plate (often phenolic, aluminum, or steel) is mounted flush into an opening cut into your table saw’s extension wing or a custom-built auxiliary table. Your router then mounts directly to the underside of this plate.
2. Integrated Router Table Extension: Some higher-end table saws come with a dedicated extension wing specifically designed to house a router. These are often made from cast iron or heavy steel, offering maximum stability.

For most users, a router plate insert into an existing extension wing is the most accessible and cost-effective option.

Installation Steps for a Router Plate Insert

Follow these steps carefully to install your router mount:

1. Prepare Your Extension Wing: If you’re using an existing extension wing, you’ll need to cut an opening for the router plate. Use a router with a template guide and a straight bit, or a jigsaw, to create a precise opening. Ensure the opening is slightly smaller than the plate’s rabbet to allow it to sit flush.
2. Mount the Router Plate: Carefully drop the router plate into the prepared opening. It should sit perfectly flush with the table saw’s surface. Secure it from underneath with screws, if provided, or shims if needed to achieve perfect flushness.
3. Attach Your Router: Invert your router and align its base plate holes with the pre-drilled holes on the router plate. Use the provided screws to firmly attach the router to the plate. Ensure it’s centered and securely fastened.
4. Adjust Router Height: Most router plates come with a lift system or allow for easy height adjustment from above the table. Familiarize yourself with this mechanism, as you’ll be using it constantly.
5. Set Up the Fence: Your table saw’s fence will now serve as your router fence. Ensure it’s clean, straight, and slides smoothly. Consider adding a sacrificial wooden fence face to prevent damage to your main fence and for better dust collection.
6. Test Run: Before any real work, do a test run with a scrap piece of wood. Check for proper bit height, fence alignment, and smooth operation.

Take your time during installation. A precise setup is key to getting accurate results.

Mastering Routing on Your Table Saw: Techniques and Table Saw with Router Mount Tips

Once your setup is complete, it’s time to put your combined workstation to work. Mastering routing on your table saw involves understanding proper techniques and adhering to best practices.

Essential Routing Techniques

Here are some fundamental techniques for using your table saw with router mount:

• Climb Cuts vs. Conventional Cuts: Always feed the workpiece against the rotation of the router bit (conventional cut) unless you are making a very light pass on a specific type of material, or if you are specifically advised otherwise for a particular operation. Climb cutting can be dangerous and lead to kickback.
• Multiple Passes: Don’t try to remove too much material in a single pass, especially with larger bits or harder woods. Take several shallow passes, incrementally lowering the bit or moving the fence, to reduce strain on the router and prevent tear-out.
• Featherboards and Hold-Downs: These accessories are invaluable for keeping your workpiece tight against the fence and down on the table, ensuring consistent depth and preventing chatter. Use them for almost every routing operation.
• Starting and Stopping: Always turn the router on *before* the workpiece touches the bit and turn it off *after* the workpiece has completely cleared the bit.

Table Saw with Router Mount Best Practices

To get the most out of your setup and ensure safety, follow these best practices:

• Use Sharp Bits: Dull bits cause burning, tear-out, and put extra strain on your router. Keep your bits sharp or replace them when they show signs of wear.
• Dust Collection is Crucial: Routing generates a lot of fine dust. Connect your dust collector to your table saw’s dust port and consider an auxiliary dust port for your router fence. Good dust collection improves visibility and keeps your lungs healthy.
• Fence Setup: For most edge routing, the fence should be flush with the bearing of the router bit. For profile bits without a bearing, or for grooving operations, ensure the fence provides adequate support.
• Outfeed Support: For longer workpieces, outfeed support is just as important for routing as it is for sawing. This prevents the workpiece from tipping and ensures consistent results.
• Patience and Planning: Don’t rush. Plan your cuts, set up carefully, and make test cuts on scrap material before working on your project pieces.

These table saw with router mount tips will help you achieve professional-looking results and maintain a safe working environment.

Navigating Challenges: Common Problems with Table Saw with Router Mount and Their Solutions

Even with the best setup, you might encounter a few hiccups. Knowing how to identify and solve common problems will save you time and frustration.

Router Plate Not Flush

Problem: The router plate sits either above or below the table saw surface, causing the workpiece to snag or tilt.

Solution: Use shims (plastic, metal, or even tape) underneath the plate to raise it, or plane/sand the rabbet in your extension wing slightly to lower it. Achieve perfect flushness; even a fraction of a millimeter can affect accuracy.

Tear-Out or Chipping

Problem: The wood fibers tear out or chip, especially on the exit side of the cut.

Solution: Ensure your router bit is sharp. Take shallower passes. Use a zero-clearance insert around the router bit opening on your plate. A sacrificial fence face can also provide support and reduce tear-out at the exit point. For particularly brittle woods, score the cut line with a utility knife beforehand.

Burning on the Workpiece

Problem: Dark, scorched marks appear on the wood surface during routing.

Solution: This indicates the bit is dull, you’re feeding too slowly, or you’re taking too deep a pass. Use a sharp bit, maintain a consistent feed rate (not too slow), and take multiple, shallower passes. Also, ensure your router’s RPM setting is appropriate for the bit size and wood type.

Inconsistent Depth of Cut

Problem: The routed groove or edge is not uniform in depth along the workpiece.

Solution: Check that your router is securely mounted to the plate and not shifting. Ensure the workpiece is held firmly against the table and fence throughout the cut, using featherboards and consistent pressure. Also, verify that your router’s depth adjustment lock is tight.

Excessive Vibration

Problem: The router and table vibrate excessively during operation.

Solution: This could be due to an unbalanced or damaged router bit (inspect it carefully). Ensure the router is tightly mounted to the plate. If using a large or heavy router, confirm your table saw’s extension wing is sturdy enough to support the weight without flexing. A heavy-duty plate also helps.

Addressing these common problems with table saw with router mount proactively will ensure smoother operations and better results.

Safety First: Essential Practices for Your Combined Setup

Working with any power tool demands respect, and combining a table saw and router doubles that imperative. Your safety is paramount. Always prioritize safe practices.

General Safety Guidelines

• Read Manuals: Always read the owner’s manuals for both your table saw and your router before operating, especially after integrating them.
• Wear PPE: Always wear appropriate personal protective equipment, including safety glasses (at minimum), hearing protection, and a dust mask.
• Unplug Before Adjusting: Never adjust a router bit, fence, or make any changes while the router is plugged in. Unplug the router from the power source.
• Clear Workspace: Keep your work area clean and free of clutter. Ensure good lighting.
• No Loose Clothing/Jewelry: Remove loose clothing, jewelry, and tie back long hair to prevent entanglement with rotating bits.

Specific Router Table Safety

• Secure Workpiece: Always use featherboards, push blocks, and hold-downs to keep your workpiece firmly against the fence and table. Never freehand a cut.
• Proper Feed Direction: As mentioned, always feed the workpiece against the rotation of the bit. Incorrect feed direction can cause dangerous kickback.
• Router Bit Selection: Use the correct router bit for the task. Ensure bits are sharp and free of damage. Never use a bit that’s too large for your router or that exceeds its RPM rating.
• Depth of Cut: Take multiple shallow passes rather than one deep pass. This reduces strain on the router and the risk of kickback.
• Mind the Gap: Ensure the opening around the router bit on your plate is as small as possible, ideally using a zero-clearance insert. This prevents small pieces from falling into the router cavity and improves workpiece support.

A momentary lapse in safety can have serious consequences. Be vigilant, be cautious, and always err on the side of safety.

Maintaining Your Investment: A Table Saw with Router Mount Care Guide

Proper care and maintenance will ensure your table saw with router mount setup remains accurate, reliable, and safe for years to come. This also ties into sustainable and eco-friendly practices by extending the life of your tools.

Regular Cleaning

• Dust Removal: After each use, thoroughly clean all dust and debris from the table saw surface, the router plate, and especially around the router itself. Compressed air can be helpful, but always wear eye protection.
• Bit Cleaning: Router bits accumulate pitch and resin, which causes burning and dulls the edge. Use a specialized router bit cleaner or oven cleaner (with caution and gloves) to remove buildup.

Inspection and Lubrication

• Check Fasteners: Regularly inspect all screws and bolts securing the router to the plate and the plate to the table. Tighten anything loose.
• Router Collet: Keep your router’s collet clean and free of debris. A clean collet ensures the bit is held securely. Never overtighten the collet nut without a bit inserted.
• Table Surface: Keep your table saw’s cast iron or steel surface clean and waxed (using a non-silicone paste wax) to prevent rust and allow workpieces to slide smoothly.
• Router Lift Mechanism: If your setup includes a router lift, keep its threads clean and lightly lubricated according to the manufacturer’s instructions.

Sustainable and Eco-Friendly Practices

Thinking about the long-term impact of your tools:

• Longevity Through Care: By meticulously maintaining your tools, you extend their lifespan, reducing the need for premature replacements. This is inherently sustainable.
• Efficient Material Use: Precise cuts from a well-maintained router mount reduce waste, making your woodworking more eco-friendly.
• Dust Management: Effective dust collection isn’t just for health; it keeps fine particles out of the environment and can often be composted (for untreated wood dust) or properly disposed of.
• Sharpness Matters: Keeping bits sharp not only improves cut quality but also reduces energy consumption from your router as it doesn’t have to work as hard.

A little care goes a long way in ensuring your integrated workstation serves you well for countless projects.

Frequently Asked Questions About Table Saw with Router Mount

What kind of router can I use with a table saw mount?

Most fixed-base routers can be mounted under a router plate. Look for a router with sufficient power (1.5 HP or more is ideal) and a robust base that can be securely attached to the plate. Plunge routers can also be used, but you’ll primarily use their fixed-base functionality when mounted.

Can I make curved cuts with a table saw router mount?

No, a table saw router mount uses the table saw’s fence, which is designed for straight-line routing. For curved cuts, you would typically use a handheld router with a template or a pin router setup, which is a different beast entirely.

Is a table saw router mount as good as a dedicated router table?

For most straight-line routing tasks, a well-set-up table saw router mount can be just as good, if not better, than many dedicated router tables, especially due to the superior fence system. Dedicated router tables might offer more specialized features like larger work surfaces or unique fence designs, but for general use, the integrated setup is excellent.

How do I manage dust when using a router on my table saw?

Effective dust collection is key. Connect your shop vacuum or dust collector to your table saw’s main dust port. Additionally, consider adding a dust port to your router fence, often a 2.5-inch or 4-inch port that can be hooked up to your dust collection system directly above the bit.

What type of router bits are best for this setup?

High-quality carbide-tipped router bits are recommended for durability and sharpness. The specific type of bit depends on your project: straight bits for dados and rabbets, chamfer bits for edge profiles, round-over bits for softening edges, etc. Always ensure the bit shank size matches your router’s collet.

Integrating a router with your table saw is a smart, efficient way to expand your woodworking capabilities without expanding your workshop footprint. It’s a testament to clever tool utilization that empowers you to tackle more complex and refined projects.

Remember, precision in setup, adherence to safety protocols, and consistent maintenance are the cornerstones of success with this versatile combination. Take your time, learn the nuances, and you’ll find your table saw with router mount quickly becomes one of the most valuable assets in your shop.

Keep those projects flowing, stay safe, and keep on building!

• Author
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Jim Boslice

Jim Boslice is a power tool enthusiast who tests, reviews, and shares practical guides to help DIYers and professionals choose the right tools for every project.

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