I had test fitted the table top and mobile base last week. This week, I have to add the sides to the MDF top and fit them to the Incra TS III rails.    The manufacturer warns that the rails should NOT support the weight of the insert top, so I also have to add some levelers to the table base.        This photo is from later in the day but will give you an idea of what I have to do next. The white section is the router table insert that I have built up from 3 layers of 1/2" MDF plus a Formica top. It is 24" wide. The saw table is 29" wide, so my plan is to use "engineered lumber" that I have glued up from 3/4" birch ply. I am orienting the laminated pieces so that I get the greatest strength and the least chance of flex.  In this pic, I am using a long straight edge to align the table saw table with the insert table...but that comes later.     I have laminated hardwood ply until I got the exact total dimension of 29" — the depth of my table saw. The glue-up ended 1/16th over, which I removed with the thickness sander bit by bit. I wanted the width of the insert to be exactly the same as the table saw.    My next task is to attach the side laminations to the MDF table. I need mostly lateral alignment, so I opted to use 3/4" birch dowels. My plan is to drill all the way through the side and then about 3" into the MDF.    Here I am marking hole positions on the sides that will be in the center of the MDF composite.    At the drill press, I use a 3/4" Forstner bit to drill where I have marked. Since the Forstner bit is relatively short, I will have to make the hole in steps. At the drill press,  I have enough drill length to get almost through the side. I like the Forstner bit since it gives the smoothest entry.   With all of the holes started at the drill press, I now carefully align the side laminations with the MDF top. I have the entire assembly turned over and am using the Quick-Clamp to hold the insert table to the table saw top. I use the table saw surface to help me align the surfaces.    I use the pre-drilled holes as guides for using a spade bit to drill into the MDF.  This bit gives me the total length I need.    I dab some polyurethane glue on the dowel. The dowel is a very tight fit, but the expanding polyurethane will make it even tighter.   With the assembly clamped together, I tap the glued dowels in place.    The dowel is in as far as it will go. I will sand the end flush when it has set.    While the top is setting, I turn to the mobile base. I am using leg levelers, but at the top of the frame where I will install them and use them to lift the top. This will give me the fine height adjustment I need for the table.    The levelers are tapped into approximate position and then secured with two screws.     The levelers can be adjusted from below with an Allen wrench. They should work well (but not without some new problems — I will come to them.)    Well much to my surprise, the levelers tilted the side pieces. I had not taken into consideration that the sides and ends are attached by one dowel-connector. This works fine to hold the legs solid, but quickly twists if you put a twisting motion to them ... as the levelers do.    The solution is easy. I cut a 1 X 3 and insert it between the rails. A couple of dry wall screws lock it in position and it keeps the sides from twisting.   Main Menu Previous  Page   (Past Chapter)        Next Page