Let me take a second to explain how I plan to make the top.  MDF (3/4") is often used and the complaint is that it can flex — not good if you want a perfectly flat work table.    1/2" MDF is available at my home center in 2' X 4' panels. I purchased 3 and plan to laminate them together to get a more substantial top. I will further support this top and show that later on.    The arrow indicates a ledge on the top panel of 3/16" depth. The Rout-R-Lift will sit on this.    The panel I just cut is the bottom panel and has the exact opening of the Router-R-Lift.          I use the "bottom" panel to make the first cut on the "top" panel. The schematic drawing that came with the plate shows cutting the ledge 3/16" deep* and 3/4" wide. I elected to use a guide bushing and a small radius bit that will give me a 5/8" ledge. It is slightly smaller that the recommended, but as you can see in the "art" above, I have the middle panel which will be the same opening so there should be plenty support.    *Be sure the check the instructions that come with your plate. The 3/16" dimension has been changed on more recent versions to allow for new levelers.     Now I use the bottom panel and the bearing cutter to cut the ledge with a 3/16" depth.    If you are a bit confused, I don't blame you. It is complicated. The reason I go thru these routing steps rather than to cut to measured lines is that the finished result is extremely accurate and looks very professional.       I want to add a top surface of matte white Formica. I could have mounted this to the top sheet and machined it at the same time as I made the ledge cut. I didn't think of it. It is typical to add this surface after all is done and then use a trim bit. Unfortunately, the trim bit bearing needs more depth that the 3/16" ledge allows. I use the bottom panel once again to serve as a guide for cutting the Formica opening.   To glue the layers together, I use a 2-part resin mix that is very strong and gives the layers rigidity. I felt that the typical wood adhesives were too flexible.    Since I have quite a bit to glue up (three panels and the Formica), I mix the adhesive according to the instructions and use a mix ratio that will give me maximum work time.    I use a roller to spread it out evenly. It feels and looks like a brown latex paint at this point.    I am nearing the completion of the glue up. I use the spring clamps to hold the layers as I do final adjustments. This is the time to make sure that all the inside surfaces of the opening are exactly aligned.    Once all aligned, I carefully clamp the sandwich together until the resin mix is completely cured—about 2 hours. Main Menu Previous  Page Next  Page