Router base materials?

[ElectricFeet]

I’m about to make a new extended base for my 1010 router (similar to the one on the late “Running pad with chip deflector” ex cat number 493139 )

I’m not sure what material to use. Acrylic (plexiglass)? Polycarbonate?

I don’t want to use polyethylene as I can’t use epoxy glue with it (for another part of the project).

Does anyone know the name of Festool’s material? And whether it’s epoxy glue-able?

 

[Cheese]

493139 was fabricated from phenolic.

 

[woodferret]

I wonder how that compares to the next extender in the accessory kit.

 

[ElectricFeet]

493139 was fabricated from phenolic.

Thanks [member=44099]Cheese[/member]  [big grin] Good to know. And it’s expoxy-able too.

I wonder if it’s always smooth and perfectly flat like cast acrylic. (I’ll be buying online, so won’t be able to check.) Or whether I could end up with a wavy rough sheet that would be perfect for a router base  [doh]

Any idea what’s the fabric-ey resiny stuff that they use on the 1010/1400 router bases?

I wonder how that compares to the next extender in the accessory kit.

What was great about 493149 is that it allowed you to add the chip collector with magnets. So I’ve ordered all the bits on EKAT and plan on making the base — which isn’t orderable — myself (I have a Shaper Origin, so I should be able to accurately make the spaces for the parts).

 

[Cheese]

I wonder if it’s always smooth and perfectly flat like cast acrylic. (I’ll be buying online, so won’t be able to check.) Or whether I could end up with a wavy rough sheet that would be perfect for a router base  [doh]

What was great about 493149 is that it allowed you to add the chip collector with magnets. So I’ve ordered all the bits on EKAT and plan on making the base — which isn’t orderable — myself (I have a Shaper Origin, so I should be able to accurately make the spaces for the parts).

Phenolic is composed of sheets of thin materials bonded together with a thermosetting resin. It will always have a very smooth surface and be extremely flat.
https://www.emcoplastics.com/phenolic/#:~:text=Phenolics%20are%20the%20result%20of,its%20high%20resistance%20to%20flexing.

I purchased my 1010 back in 2016. I started to look for the 493149 plate about 2 years later and have still never found one. The folks that have them just don't want to sell them so making your own is the only alternative.

 

[ElectricFeet]

Phenolic is composed of sheets of thin materials bonded together with a thermosetting resin. It will always have a very smooth surface and be extremely flat.

Thanks [member=44099]Cheese[/member]  This may be a US English / British English thing, complicated by my living in Italy. If you say “phenolic” in Italy (“fenolico”), they generally understand it to mean marine grade plywood. Searching for “phenolic sheets” leads me to products that they also label as bakelite (which conjures up memories of (greying) black telephones in old people’s homes in the 70s). I sometimes buy high-quality materials from Germany too and have no idea what they call it.

I’ve found one supplier that shows a picture of the fabric stuff, even though they call it bakelite — it looks like it should do the job. I’ll wait for the spare parts to arrive and check the tolerances / thicknesses before dropping any money on it.

Thanks for your help.

 

[woodferret]

Alternate name might also be garolite.  That said, you might want Micarta which is less fiberglass, more linen/paper/non-scratchy.

 

[MikeGE]

I sometimes buy high-quality materials from Germany too and have no idea what they call it.

This is what I bought through the German Amazon site when I made an extended base for my OF 1400:

https://www.amazon.de/dp/B09B2FWW25

It is thicker than the stock base, but appears to be the same phenolic material.

 

[ElectricFeet]

Alternate name might also be garolite.  That said, you might want Micarta which is less fiberglass, more linen/paper/non-scratchy.

Garolite gets me nothing in searches here. Micarta is intriguing. I’ve wanted to buy it in the past, as it looks like a great alternative for someone like me who has a Shaper Origin, but not a 3D printer. However, it always seems to be sold to knife-maker hobbyists in stupidly small pieces at exorbitant prices.

I think I need to go more off the beaten internet path to find the perfect candidate.

Food for thought; thanks to both.

 

[ElectricFeet]

This is what I bought through the German Amazon site when I made an extended base for my OF 1400:
https://www.amazon.de/dp/B09B2FWW25

It is thicker than the stock base, but appears to be the same phenolic material.

Yay, thanks [member=70363]MikeGE[/member] !  I in fact need the thickness, in order to embed the magnets. I will only know for sure once the parts arrive. But now I know what it’s called in German, that gives me new avenues. Thanks!

 

[Crazyraceguy]

I never knew that there was a magnetic attachment version for the OF1010? That is the one thing I find lacking in it, compared to the OF1400. Although the magnets are nicer than the clips. The extended base (table widener) for the OF1400 is magnetic.
Overall that's a good idea. I use my OF1010 with a bushing most of the time, so it wouldn't be some radical game changer. I will look into it anyway  [big grin]

 

[ElectricFeet]

I never knew that there was a magnetic attachment version for the OF1010?

“Was” being the appropriate tense. It was discontinued some time ago. No idea why. But you can get the spare parts in EKAT and make your own.

 

[MikeGE]

Yay, thanks [member=70363]MikeGE[/member] !  I in fact need the thickness, in order to embed the magnets. I will only know for sure once the parts arrive. But now I know what it’s called in German, that gives me new avenues. Thanks!

Here is the vendor's website for the phenolic board.  It's available in thicknesses from 0.5 to 20mm.
https://www.masterplatex.de/epages/...th=/Shops/62236671/Products/"PFCC201/Hgw2082"

 

[Packard]

You can drill and tap directly into phenolic.  It is dimensionally stable and resistant to most chemicals we see in a woodworking shop.

It will dull bits and blades rather quickly.  Carbide is recommended.

If you don’t need the transparency of acrylic, then I would use the phenolic.  It tends to be a bit pricey, but still a good material for router bases.

 

[ElectricFeet]

If you don’t need the transparency of acrylic, then I would use the phenolic.  It tends to be a bit pricey, but still a good material for router bases.

Thanks [member=74278]Packard[/member] . I have some acrylic lying around and it was my fallback choice. But I was worried it would get dents and scratches, which would transfer to the workpiece. Or, worse, it would shatter if (when) it gets dinged, or the screws are tightened too tight (don’t ask me how I know). Hence my question also including polycarbonate as an option — but that also can be very scratchy when it is itself scratched.

I don’t need the transparency, although the magnets would look cool in a transparent material

Now I know what Festool uses and I have [member=70363]MikeGE[/member]’s link for a German supplier, I think I’ll stick with phenolic.

Thanks to all.

 

[Crazyraceguy]

I never knew that there was a magnetic attachment version for the OF1010?

“Was” being the appropriate tense. It was discontinued some time ago. No idea why. But you can get the spare parts in EKAT and make your own.

Do you happen to know the item number for the chip catcher? I can't seem to find it.

 

[Cheese]

I'd never use plexiglass/acrylic as a router base. It's just the wrong material for the wrong application. If you need to see through the router base, great then use the stuff. But if not, just go with better products and there are a lot of better alternatives. Even aluminum and wood are better materials. Actually, an aluminum base with an HDPE covering works pretty well. The HDPE is really slick as a sliding surface.

 

[Sparktrician]

I'd never use plexiglass/acrylic as a router base. It's just the wrong material for the wrong application. If you need to see through the router base, great then use the stuff. But if not, just go with better products and there are a lot of better alternatives. Even aluminum and wood are better materials. Actually, an aluminum base with an HDPE covering works pretty well. The HDPE is really slick as a sliding surface.

Phenolic-covered baltic birch is also great - and quite slick.  [smile]

 

[ElectricFeet]

Do you happen to know the item number for the chip catcher? I can't seem to find it.

From EKAT:
[attachimg=1]

From my parts supplier's invoice:
466885 COVER,LEFT KSF-OF 1010      €1.78
466389 BEARING RING OF 1400 EBQ      €8.45
467877 RETAINER KSF-OF 2000      €7.00
466390 HOOD OF 1400 EBQ      €2.57
770273 COUNTERSINK DIN 965-M4X8-8.8      €1.39
228568 OVAL HEAD SCREW DIN 7985-M4X12-4.8      €1.39

So for an OF 1010 you can make the whole thing for $25 or so, plus the cost of the base material that you decide to use.

Interestingly, my parts supplier lists 2 of the parts as OF 1400 parts:
- 466390 The hood: Seems to be used for both. Makes sense to use the same part for the same function.
- 466389 The bearing ring: According to EKAT, this is not an OF 1400 part, so I don't know why they list it as such (in English and Dutch, but not in Italian and Spanish: go figure). I'm now debating whether to write an email to the supplier before they ship it out to me in a couple of weeks. Sigh. Don't think I can be bothered. It's the most expensive of the parts -- all of $9 or so -- so I presume it's either aluminium or -- this would be awesome -- contains the magnets already.

Will update when the parts arrive.

 

[Packard]

For additional background:

Phenolic sheets are available using paper, linen or fiberglass reinforcement. 

We used the cheapest (paper) for our welding fixtures where I used to work.  Many of these fixtures withstood 50,000 or more cycles. 

Opting for linen or fiberglass versions is probably a waste of money.  Fiberglass is used in high heat environments (I’ve been told).

Small pieces are available through Amazon, and I think are sold by Rockler, Lee, and others.  Or order directly from the seller for the same price as on Amazon.