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Page 1 of 12DP-00064 ©Copyright Meredith Corporation 2003

Tilt-Top Router Table An open-and-close shop tool designed for convenience

C ount the features of this fully loaded

router table, and you’ll quickly conclude

that you’ve got to have one. For starters

the table flips up for easy changing of

bits and checking bit height. It’s topped

by an accurate, easy-to-build fence. A

sealed compartment underneath, fitted

with a vacuum port, takes care of

sawdust. Below that, you’ll find a slide-

out shelf for storing all kinds of bits and

accessories. Plus, we offer an optional

table design for use with an aftermarket

fence.



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Page 4 of 12

Add the shelf, door,and base trim1 Cut the router-bit shelf (P) andsmall-bit holder (Q) to size.Locating the holes to properly space your particular bits, mark the centerpoints, and then drillholes in the shelf for your large-

diameter bits. Now drill holes inthe bit holder (Q) for your smallbits. The small-bit holder worksgreat for straight bits, which

would fall through the holes inthe shelf (P). Next, glue andclamp the bit holder to the shelf.2 Cut the base-trim supportpiece (R) to the size listed, andscrew it to the front of thecabinet.3 Cut the door (S) to the sizeshown in Drawing 2. Rout a fi"

round-over along the sides (notthe top and bottom) of the door.4 Drill holes in the door for attaching the wire pull later.5 Attach the hinges wheredimensioned, and mount the door to the cabinet. Add the magneticcatches and strike plates to thedoor and cabinet.6 Cut the base-trim pieces (T) to

size plus 1" in length from solidstock. Rout a fi" round-over alongthe top outside edge of each trimpiece. Miter-cut the trim pieces tolength. Working from the insideof the cabinet, drill countersunk mounting holes, and then glueand screw the trim pieces to the

bottom outside of the cabinet.7 Turn the cabinet upside down,and nail four glides in place.

Here’s how to addthe tilting top Note: On this project, we give youthe option of two different tabletops.The instructions below detailbuilding the 28" square standard top. You’ll also find dimensions for the larger 28×36" table, shown inPhoto C on Page 11 , that’s

designed to work with an Incra JigUltra.

1 Cut two pieces of ‡" MDF to29" square for the tabletop (U),shown in Drawing 3, and detailedin Drawings 6 and 7.2 Glue and clamp the two piecestogether face-to-face. To achieveuniform clamping pressure in the

center of the lamination, drillseveral pilot holes from what willbecome the underside of thetabletop, and then drive several

#8×1‹" screws into the upper lamination. Next, using clampsalong the edges, secure the twopieces tightly together until the

glue dries. Now remove all thescrews so you won’t hit them inthe following steps.3 A Cut the laminated router top(U) to finished size (28" square),radiusing the corners at 1".4 Cut two pieces of plasticlaminate to 30" square. Apply contact cement to all matingsurfaces, and adhere the laminateto both surfaces of the tabletop(U). Use a rubber roller to ensurea good bond between the

laminate and MDF.5 Using a trimming bit, rout theedges of the laminate flush with theedges of the tabletop as shown inPhoto B.6 Cut or rout a dado in the top(U), where dimensioned, to forma slot that fits your miter-gaugeguide bar.

Using contact cement, adhere the two oversized pieces of plastic laminate tothe laminated top. Then, rout the edges of the laminate flush.

B



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Page 5 of 12

7¤"Hinge

9"

3‡"

‹" prongless T-nut

LW

O

S

1fi"

‹-20 x 1fi" F.H. machine screw

V U

‹-20 threaded insert

3 SIDE SECTION VIEW



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Page 6 of 12

4 FORM THE ROUTER-PLATE RECESS

Centeredside-to-side

11‡ x 11‡"router plate

5"

F R O N T E D G E

U

Step 1 Position the plate 5" fromthe front edge on top of andcentered side-to-side.

U

Step 2 Trace outline of theplate onto the top of .U

U

2"

2"

10‡"

fi"

fi"

Step 3 Lay out and mark the openingcutlines inside the traced outline.

5"

Step 4 Drill a blade starthole, and cut the opening.

Cutlines

10‡"

Traced outline

F R O N T E D G E

G ui d e

b o ar d 2

G ui d e b o ar d 1

Guide board 3

Guide board 4

Step 5 Secure router plateinside traced outline withdouble-faced tape.

F R O N T E D G E

U

Step 6 Clamp the guide boards around the plate,spacing each board away from the plate Î" withbusiness-card shims.

Router plate

Spacers

Step 7 Remove the router plate and shims. Use a portable router and straight bit witha top-mounted pilot bearing. With the router base resting on the surfaces of the guide boards,adjust the cutting depth to rout ¤" deep into the tabletop. Then, guiding the bit’s pilot bearingalong the inside edges of the guide boards, rout the recess. Make additional passes, loweringthe bit each time until you reach a depth equal to the thickness of the router plate.



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Page 7 of 12

Cut the table insert into the top Note: We secured the router plate to the tabletop withscrews and T-nuts so that the plate (with the router attached) can’t fall out when tipping the tabletop back.See the Buying Guide for our source for the router plate

and hardware.1 The router plate we used (see the Buying Guide)is listed as a 12"-square plate, but actually measured abit less. Using a tablesaw, cut adjoining edges tosquare up the plate, then trim it to 11‡" square.2 Follow the seven-steps, described in Drawing 4, toform the router-plate recess in the top (U).3 Mark the centerpoints, and then drill ˇ" holes inthe corners of the router plate, where dimensioned inDrawing 7. Fit the router plate in the recess, and usethe holes as guides to drill through the corners of therecess in the top (U).

4 Using epoxy, adhere a ‹" prongless T-nut intoeach ˇ" hole on the underside side of the router tabletop.5 Carefully mark the centerpoint on the router plate. Now, bore a 1fi" hole (or one slightly larger

than the diameter of your largest-diameter router bit)through the center of the router plate.6 Countersink the ˇ" holes in the router plate for the ‹-20×1fi" flathead machine screws.7 Remove the baseplate from your router. Using theholes in your baseplate as guides, mark and drillcorresponding holes in the router plate.Countersink or counterbore the holes, as requiredfor your router, and then mount your router to therouter plate. Place the router and router plate intothe tabletop recess, and secure the plate with machine screws.

Location of part

U

R

B

28"

3‡"

fi" rabbet›" deepon top side

28"

19"

3‡"

Hingelocation

3‡"

Location of part

4‡"

15‹"

ˇ" hole

FRONT OF TABLE

V

‹" lock nut

V

W

‹" flat washer

‹-20 x 1fi" F.H.machine screw

‹" hole,countersunk

ALocations of parts

5 ROUTER TABLETOP

5a SUPPORT BLOCK DETAIL

(Bottom view)



TM

31/ 4"

3/ 4"

Dado to fitmiter gauge.

28"

28"

5"

R=1"

FRONT OF TABLE

Fence

X

1/ 4-20 threaded inserts21/ 2"

Centerline

23/ 4"

3/ 8" holes 51/ 8"

21/ 2"5"

U

Y

U

B

V

A

S

6a THREADED INSERT LOCATION DETAIL(Top view)

6 ROUTER TOP

‡"

‡"

Radius cornersto matchrabbeted recess.

ˇ" hole,countersunk for a‹-20 x 1fi" F.H.machine screw

1fi" hole,centered

7 ROUTER PLATE

Page 8 of 12



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Page 9 of 12

10"

2fi" 5" 2fi"

ˇ" slots 2ˇ" long

2" 10fi"

2"

24"

12"R=1"

27‡"

2fi"

1‡"

3"

Top view

Front viewR=1"

13Œ"

X

Y

3"

Z Z

8 FENCE

Centerline

1"

6"

15‡"

8"

7‹"

1›"

3"

›" holes, countersunk

7‹"

3‹" 3‹"

‡" stock

3"

INCRA JIG ULTRA MOUNTING PLATE

¸" shank holes,countersunk onbottom edge

Top view

1"

fl"

1‹"

V

V

Side view

PIVOT BLOCKFULL-SIZE PATTERN

‹" hole

9 PIVOT BLOCK FULL-SIZE PATTERN10

Z2‹"

2‹"

‡"

‡"



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Page 10 of 12

Dado to fitmiter gauge.

FRONT OF TABLE

3‹" 5"

36"

28"R=1"

V

1‹"-diam.plastic knob

Mounting plate

Incra Jig Ultra

‡"

3‡"

ALocations of parts

Location of part

BLocationof part

3‡"

28"

19"

3‡"

4‡"

15‹"

ˇ" hole

FRONT OF TABLE

10‡"

7‹" 7‹"

›" holes, countersunk

‹-20 threadedinserts

Hingelocation

V

Location ofmounting plate

3"

1›"

S

(Bottom view)

‹ x 1 x 12" aluminum

fi"

‹" hole,countersunkthis side

R=fi"

W

SUPPORTBAR

FULL-SIZEHALF

PATTERN

Join pattern here.

1"

5"

1"

fi"

W

SUPPORTBAR

FULL-SIZEHALF

PATTERN

Join pattern here.

11 OPTIONAL LARGE ROUTER TABLETOP

13 SUPPORT BARFULL-SIZE PATTERN

(Top view)12 OPTIONAL LARGE ROUTER TABLETOP



TM

Adding a fence system Note: In addition to the accurate,easy-to-build fence shown, we designed this router tabletop to be compatible with a number of fence systems, including the Incra Jig Ultra, below right. Before installing another brand fence, check the

m an uf ac tu re r’ s m ou nt in g requirements.1 Cut the fence (X), base (Y),and braces (Z) to the sizes listedin the Materials List and shownin Drawing 8 on Page 9. Cut themounting slots in the base (Y),

where shown.2 Lay out and cut the 1"-radius bit-clearance openings in the fenceand base. Now glue and screw these parts together, and add thebraces to form the completed

fence assembly.3 Mark the centerpoints for thethreaded inserts on the router top(U) where dimensioned inDrawing 6a on Page 8.4 Drill a fi" hole at each markedcenterpoint just through thelaminate („" deep). (We used aForstner bit to make this recess.)Switch bits, and drill a ›" hole 1‹"deep centered in each fi" hole. (If

you are using the Incra Jig, follow

the dimensions onDrawings 10, 11,

and 12.)5 Double-nut a bolt, and use it todrive a threaded insert into each hole.

Now attach the tabletopsupport1 From ‡" maple, drill the holesand cut the pivot block (V) toshape, as dimensioned in Drawing9 on Page 9.2 Transfer the support bar (W)

pattern from Drawing 13 to ‹×1"aluminum bar stock. Cut the pieceto shape, and drill a hole through one end, where marked.3 Drill pilot holes, and glue andscrew the pivot block (V) to thebottom of the router top, whereshown on Drawing 5. Then, attach the support bar to the pivot block.

Finishing and final assembly1 Remove the router plate androuter from the router tabletop.Separate the top from the basecabinet. Remove the hardware,and sand the cabinet and tabletopedges smooth. Fill any imperfections and finish-sand.

2 Prime the base cabinet. (We didthis in several coats, using asanding block with 220-gritsandpaper between coats tosmooth the primer.) Paint the basecabinet as desired. Apply a clear finish to edges of the router tabletop.3 Hinge the router top and door to the cabinet. Reattach themagnetic catches and pulls. Then,reattach the router with attachedplate to the router tabletop.

4 Attach the fence system of your choice. Attach a power switch tothe cabinet, and plug the router cord into the switch. Fit your

vacuum hose into the opening, and you’re ready for business. ¿

Written by Marlen Kemmet

Project design: Jim Downing

Illustrations: Roxanne LeMoine; Lorna

Johnson

Photographs: Hetherington

Photography

‡ x 49 x 97" Medium-density fiberboard

‡ x 49 x 97" Medium-density fiberboard

‡ x 7‹ x 96" Maple

Scrap to form guide boards

R

BL

A K

M

OP

A

N

U U

S

D E F G H I J

QT

C

TTTV

, , , , , , ,

(MDF measures 49 x 97")

Y

‡ x 3fi x 48" Maple

X Z

Cutting Diagram

Page 11 of 12

C



TM

Page 12 of 12

*Parts initially cut oversize. See theinstructions.

Materials key: MF–medium–density

fiberboard, M–maple or birch,LMF–laminated medium-density fiberboard, A–aluminum.

Supplies: ›×12×12" phenolic router plate, #8×1‹" flathead wood screws, 1fi"continuous hinge 19" long with mountingscrews, ‹-20×1fi" flathead machinescrews (6), ‹" flat washers (2), ‹"prongless T-nuts (4), power switch, onepair of cabinet hinges (we used Amerock

#BP-5988-M26), 1¤" glides (4), 3fi" wirepulls (2), pair of magnetic catches andstrike plates, plastic laminate, contact

cement, ‹-20 threaded inserts (4), four-arm knobs (2), ‹–20×1fi" bolt trimmed to1¤" long, ‹×1" aluminum bar stock for support bar (part W), primer, paint, andclear finish.

Buying GuideTilt-top router-table kit. The kitcontains everything noted in the Supplieslisting above except the plastic laminate,power switch, contact cement, primer,paint, and finish. Kit no. TTRT, $54.95

ppd. Schlabaugh and Sons Woodworking,720 14th St. Kalona, IA; 800/346-9663.

Incra Jig. Several models areavailable. For more information, contactIncra at 972/245-9975 or

www.incra.com.

CABINET

A side ‡" 19" 35" MF 2

B back ‡" 20fi" 35" MF 1

C* cleats ‡" ‡" 5Œ" M 2

D* cleats ‡" ‡" 4Œ" M 2

E* cleats ‡" ‡" 26" M 2

F* cleats ‡" ‡" 13Å" M 2

G* cleats ‡" ‡" 7Í" M 2

H* cleats ‡" ‡" 18‹" M 4

I* cleats ‡" ‡" 17fi" M 2

J* cleats ‡" ‡" 19" M 2

K bottom ‡" 19" 19" MF 1L sloped dust panel ‡" 15Œ" 19" MF 1

M bottom dust panel ‡" 7‰" 19" MF 1

N dust bin front ‡" 3" 19" MF 1

O support ‡" 7¤" 19" MF 1

P shelf ‡" 18¤" 18Œ" MF 1

Q bit holder ‡" 1fi" 16‡" M 1

R support ‡" 4" 20fi" MF 1S door ‡" 20fi" 30Œ" MF 1

T* base trim ‡" 4" 22" M 4

M mantel 1fi" 10Œ" * SS *

U* top ‡" 28" 28" LMF 1

V pilot block ‡" 1" 2‹" M 1

W support bar ‡" 1" 12" A 1

W mantel 1fi" 10Œ" * SS * X base ‡" 10fi" 24" MF 1

Y fence ‡" 3" 27‡" M 1

Z braces ‡" 2‹" 2‹" M 2

Cabinet

Bill of Materials

Matl. Qty*.T W L

FINISHED SIZE

Router Table

Fence



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