How to Make a Router Table for a Plunge Router

Any power tool can be quite dangerous. Most handheld tools that are used when strapped onto a bench or rail can slip and also become quite fatal. That’s why it is important that you get the best solutions to any power tool that you choose to use.

With that mentioned, let me come down to a plunge router. Whether plunged or not, any router is essentially a very dangerous tool. Since it is made out of a drill that spins at higher speeds, it can easily slip out of place and cause some harm.

Even worse is if the router spins with additional torque. Lucky for us, there are a few ways to keep your router under check. One of the most efficient ways is to build a router table. It will keep you safe and help you to work easily.

So how can you make a good router table for a plunge router? Here is a simple guide on how to make a router table for a plunge router ?.

The guide is easy to understand and will work for any router that’s powerful enough to make any type of cut through lumber.

Tools and Materials

The very first step when you want to make a router table for a plunge router is to gather the right tools and materials. Here is what you will need for the whole process to be a successful one for you.

Plunge router (edge guide)
Straight bit (1/2″ bit)
V-Groove bit
2 Carriage bolts with penny washers
Wing-nuts for the bolts
Hole saw (1 1/2″)
3/4″ ply (14″x18″)
Clamps
Pencil
Zip tie (holding power trigger)
Circular saw to cut your Ply

Step I: Mark the Mounting Board and Clamps

First, cut your ply to size. I cut my mount to 14″ square. Thankfully, any router table doesn’t really need to be so huge. A router is a small tool. Also, make sure that you mark out and then cut some lengths of the ply as the clamping pieces.

Step II: Determine the Router’s Position on Board

Once you get the right board size, determine the position of your router . Make sure that you leave some space that you will use as support all around the router. If the position is okay you can draw around the main footplate.

Step III: Make Your Recess

Now it is time to make the recess. Personally, I saw that the depth of my plunge wasn’t far enough. This is because I used plywood with a 3/4″ depth. So, I decided to recess the router. However, I used the bars from my edge guide and my router as the main support when working on any heavy piece.

Step IV: Make Grooves and Prevent Play

Once you have made the recess, you should ensure that the router fitted in nicely. To do that, you can run two shallow V-Groves. The grooves should go up the board and lie in the place where the bars would fit.

With a V-Grove, the bars should center themselves. Nonetheless, you can also go with a shallow groove that has a straight bit and the same width as your bars. Even so, make sure that you don’t have any form of vertical play!

Step V: Attach Clamping Blocks

To attach the clamping blocks, you need to line up the main grooves in your clamping blocks first. Then clamp them down at the place where they will not interfere with the main footplate of your router.

Use the bolts to make this possible. I always recommend two bolts for every clamp for a better grip on every bar.

What You Must Do When Clamping Blocks

When it comes to How to Make a Router Table for a Plunge Router, the block must be clamped at some point.

But how best can you do that? You can use a hand drill since it allows you to drill vertically. This will help you to make better holes that will make the clamps tighter and even much more secure.

Nonetheless, if you are good with one or two bolts per clamp that should be fine too. Just make sure that before you fit the bolts you recess them into the main surface of your board.

Step VI: Time to Enjoy

With all your sides fixed, your router table should be ready for your plunge router. You should be ready to fit in the router and make good use of it. It is time to enjoy.

Additional Tips

It is important to note that when making a recess, you can use a fence to easily cut out one edge of your router. This should make your work easy.

Even so, you shouldn’t also fight so much for a snug fit, but if you can, you can go for it. It helps to prevent any forms of slip.

More importantly, you shouldn’t go too deep/too fast as this can easily rip the main table material. So, just drill a hole that the router’s bit can easily fit through as this will make your work with the router easy.