New Product - "CMT Router Table with Large Insert"

Last week, I posted this picture with the announcement that Beth and I would be starting a new project — an "Insert Plate Garage.'
	This is what started the idea some months ago. Marc Sommerfeld sent me a new product, the new Pocket-Pro Joinery System developed by Marc and CMT (photo is from CMT's website.) I have used it on a number of projects but simply clamped the base to a worktable.    But this picture intrigued me. Since these insert plates are so well made and fit so exactly, I asked myself the question: "What other shop tasks could use this concept?"
I shared my thoughts with Beth. It didn't take long to look at how we use the router table — I came up with a practical need for 5 insert plates. And, if I need this many plates, I also need a garage for them — one that would keep the tools safe and sound.
	Beth starts by measuring the tools that we will mount on insert plates. You can see the CMT/Sommerfeld Raised Panel Set in the center of the picture. I am planning the "garage" around that product and the tasks of making raised panel doors. I want to include the following insert plates:      1) large router with speed control for the large raised panel bit; 2 and 3) 2 smaller routers for the rail and stile bits; 4) the Porter Cable Portable Oscillating Spindle Sander (already mounted at the right) and 5) the CMT/Sommerfeld Pocket-Pro Joinery set, far right.
Choosing the right router is going to be a bit of a task. Beth is holding the PC 690. It is a gem of a router that I have used for years, but it works only at the speed of 22,000 rpm — great for a lot of routing jobs, but too fast for the rail and stile bits which, because of their width, should be run at 13,000 rpm.
	This Porter Cable plunge router model (PC 8529) is a recent addition to their lineup and sports a 2hp motor and has variable speed and a soft start. In the back ground you can see that I have one unit already mounted in the insert. It has the same hole sizing as the PC690 which makes it easy to change models.
This is the Porter Cable Portable Oscillating Spindle Sander which I mounted during the week. I used 1/2" Finnform which is absolutely great for this use.    I used a number of router "copying techniques" to make this insert. I did photograph most of the steps, so here they are.
	I have cut a piece of Finnform (see source below) on the table saw using another insert to set the fence distances exactly to the insert dimensions. Using an 80 tooth cabinet blade gave me a very smooth edge.    I am trying to figure out where the sander would be located on the plate. Since the sander is long, I decided to place the hole offset so that the unit will "fit." The number "1" is at the Porter Cable accessory that I am using to mark the hole position. I could also use the base ("2") which I have removed. I thought I would be leaving the base off, but I see that it is an integral part of the unit's dust collection system and belongs on.
I have used some double face tape to fix the base adapter to the Finnform and am now drilling the holes that will hold the router.
	Well, I got wrapped up with what I was doing and did not photograph some small tasks in between. What I did was use the holes to attach the black adapter to the base and then used the router with a pattern bit to follow the plastic adapter. It took only a few minutes to make an exact copy of the hole. I also used one of the other plates and the pattern bit to  rout the corners exactly.    I am holding the final product — it is perfect. But, I will admit, the other plate on the bench is the earlier attempt. I countersunk the holes on the wrong side — I don't want you to think that I don't make mistakes.
Beth was admiring the "perfect" fit and then she tried to place it in the top. It fit perfectly, but there is not enough room under the top for the sander. I will either have to remount the sander or remove the small cabinet inserts underneath the top.
	This is what it looks like. I had built these storage areas to fit the Hitachi M12V exactly. Since they are installed with pocket hole screws, I should be able to remove them and trim them down to allow the new equipment to fit.