Table Saw Extension Built!

It may be hard to believe, but I have succeeded in turning my old computer desk into a router insert. It’s not installed yet, but the bulk of the work is done. I am astonished that I pulled it off.

I got out my new plunge router, figuring I would have to edge-joint some wood for the support braces under the table. Then I remembered I already had a jointed piece of a two-by-six. I checked it out, and sure enough, it was long enough and wide enough to turn into two long braces. So I ripped it on the table saw, using the Mag-Switch, and it came out perfect.

I got out the Sears drill guide and gave it a try, drilling the holes to attach the tabletop to the side braces. It works well enough for this job, although I would not call it a precision instrument. I wouldn’t dream of using it for fine woodworking, because there is too much play in the shafts that support the chuck.

I had some horrible sheet metal countersink-type things, so I drilled with a corded drill and the guide, I reamed out the holes with the Bosch cordless, and I used my Panasonic impact driver to drive the screws. It was beautiful.

I had no idea how sad and lame my Sears corded drill was until I used it beside the Bosch. It’s slower and weaker, by far.

I used my 10″ miter saw to trim everything to length, including the supports I put across each end of the table. I still have to put at least one more of these in place. I think I should run one across the table behind the router lift; I’m not sure if there is any point in putting one farther back. But I may do it just to be thorough.

The other day I bought sheet metal sawhorse brackets which turned out to be garbage, but they were useful today, because I pulled the two-by-fours out of them, jointed and ripped them on the table saw, and used them for the cross supports. The brackets will go in the trash; they’re not even good scrap.

I don’t want to try to install the table in the saw’s rails until I have something to hold it up. This strikes me as a good time to get some quality sawhorses. I’m not going to build them. Wooden ones are heavy and bulky, and you have to go through the grief of trying to find acceptable two-by-fours at Home Depot, which is not easy. I want something I can fold up and store in a small space.

This thing should be functioning tomorrow night. It won’t be pretty; the desk had two holes in it for mouse wires, and they’re still there, and I made big holes in it when I was planning to use it as a separate router table. But it ought to work very well. The top is very, very flat so far; the bracing worked. I can fill the holes in with epoxy or something, so it will look better than it does at present.

Once I have it done, it will serve as a platform I can use to make something better. I love the workbench I built, but as a woodworking bench, it’s useless. It’s too small, and it’s against the wall, and it has a big mechanic’s vise on it.

I suppose I could build a frame and fix it so I can attach MDF sheets to it with recessed bolts. That would be a good permanent solution. When the top gets damaged, take it off, rip a sheet of MDF, and put it on.

It’s fantastic, being able to do this stuff. Once I have a planer and a sled, I should be able to joint wood fairly well, so making a better table extension should be a cinch. I have to have jointed wood because the router needs a flat surface. I can’t just plop any old lumber on the garage floor and nail it together.

The Mag-Switch is amazing. It even works over the miter slots.

It has occurred to me that if I start making boxes, I may already have suitable lumber on hand. I bought some cheap spruce boards for shelves, and it looks like I won’t need them. Believe it or not, some of that wood is very pretty, and you can get box-sized pieces without knots. Might be a fun thing to start with. Beats splurging for walnut and then ruining it.

I think it’s spruce. I get my softwoods mixed up. Spruce is a perfectly nice wood. They make guitar tops out of it. I don’t know what violins are made of, but it sure looks like spruce.

I smell like a sawmill, and I still have to put everything away. I’m out.