Trim Router Table

[TealaG]

HI!  I have a Bosch colt router that I'd like to set up for rounding over edges or flush cutting since I need to do that alot.    I saw this table and got inspired:http://www.rockler.com/trim-router-table

However, I'm cheap and I look at this and think "I can do that myself".  I originally had a Rockler router table for my router and ended up replacing the top with an Incra top because I wanted to use the positioner and didn't want to extend the rockler top.  So now I have a Rockler top that I don't think I can sell locally and it's too heavy to ship.

I was at Rockler buying something else and thought...I can take my old Rockler router top and cut it smaller and make my own trim router table.  I have the fence with the bit shield etc so if I just trimmed all of that smaller, maybe it could work?  I thought that that would mean that I could recycle most of what I already have and get some use out of it.

I was thinking I could use plexiglass to make a new subbase for the colt's plunge base and make it either fit the existing hole or cut the existing hole out and still have enough material to cut a new hole in the table (reassembling the halves with dominos).  I could pop the plexi out and use it "upside down" as a large base.

What do you think?  Any better ideas?

 

[nclemmons]

With Plexiglas, I think I'd go thicker than 1/4", perhaps 3/8..  A quick search finds  you can get 12 x 24 x 3/8 at Amazon -

https://www.amazon.com/Falken-Design-CL3-8-1224-Acrylic/dp/B01DYSW2TG/ref=sr_1_6?s=industrial&ie=UTF8&qid=1532221174&sr=1-6&keywords=3%2F8%22+acrylic+sheet

A better deal would be to consider 1/4" Phenolic

https://www.amazon.com/Leecraft-BK-2-Blank-Phenolic-Sheet/dp/B0002898CQ/ref=sr_1_cc_5?s=aps&ie=UTF8&qid=1532221261&sr=1-5-catcorr&keywords=blank+router+insert

The issue with both is cutting it crisply.  A table saw won't cut it as cleanly as you might like. A router with a plastic cutting single flute bit at a slow speed could work.  A CNC would be the best alternative if there is a maker space close by or a high school or community college with a shop that might help you out. 

How about you just get a blank insert and mount your router to it?  A little more money, but likely a more finished look with less effort -

That router has a 3 1/2" or so square base, so the one consideration with a blank plate like from Kreg is that you may still need a 1/4" sub base that is maybe 5x5" to adapt the smaller router to the base with a larger insert hole.  But that could be the best alternative.  You could even use 1/4" masonite on that small of a piece with no sagging.

https://www.amazon.com/Molded-Router-Table-Insert-Routers/dp/B01M5B613B

I'd verify the current insert cutout dimensions and corner radiuses before you order a pre-made insert.

 

[TealaG]

Hi!  Thanks for your thoughts.  I actually have a precut plate (had to buy a new one when I bought the Incra table).  I need to see if there's any way to modify it so that the colt plunge base can fit.  I hear that the plunge base is easier to adjust the height on than the fixed base and well...I already own it so why not try.  I think the plunge base being larger might actually fit ok or could be easily modified with a piece of hardboard, like you suggested.    I can then trim around the rest of the table, recut the groove for the fence and I'm done.    THANKS AGAIN!!!