www.woodonline.com

Thank you for ordering a Downloadable WOOD PLAN. We hope you enjoy beinga part of this new online experience and that you have fun building your wood-working project.

Please remember that this copyrighted material is for your use only. It is unlawfulto share this file with someone else or to reprint it in any form.

Bill KrierEditorWOOD® magazine

Adobe Acrobat Troubleshooting GuideIf you can read this page, your Acrobat program is working correctly!

But you may still have problems or specific issues such as printing and

saving your Downloadable WOOD PLAN.

My printer won't print the text correctlyAlmost all printing problems are due to not enough free system resources memory. Thefiles are very memory intensive since they include graphics, text, and photos. Close allother programs/applications and print directly out of the Acrobat Reader program, notyour Web-browser.

Patterns are not printing full sizeMake sure your printer is set to print at 100% and that “print to fit” is not checked. Thesesettings are selected in the printer setup or printer options.

I can't save my file now that it's downloadedYou must save the plan when you download the file. Download the file again, except thistime try right-clicking on the red download button. A menu window will open. Select"Save target as" or "Save link as" to save the file to your hard drive. Once saved, you canopen it with Adobe Acrobat Reader.

For more details on using Adobe Acrobat Reader please visit our online help section at: http://woodstore.woodmall.com/clicherforde.html

Thank you!

http://www.woodmagazine.com

DOWNLOADABLE ONLINE WOODWORKING PLANS

®

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

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

Count 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.

TM

Page 2 of 12

First, build the cabinet1 Cut the cabinet sides (A) and

back (B) to sizes listed in the

Materials List from ‡" medium-

density fiberboard (MDF). As noted

on the Cutting Diagram on Page11, MDF measures 1" wider and

longer than regular 4×8' sheet

goods.

2 Using Drawings 1 and 1a for

reference, mark the centerpoint,

and cut the vacuum hose hole in

the left-hand side panel (A) to fit

your vacuum hose. (We drilled a

blade start hole, and cut the hole

to shape with a jigsaw.) To

prevent chipping, rout a ¤"

chamfer along the inside and

outside edges of the hose hole.

3 Mark and cut a notch in the

right-hand side panel for the cord

from the router to exit the cabinet.

4 From ‡" solid stock (we

recommend maple or birch), cut

the ‡×‡" cleats (C–J) to the

lengths listed in the Materials List.

5 Next, mark the locations of the

cleats on the inside face of each

side panel (A), as shown in

Drawings 1 and 1a. Then, drill

countersunk mounting holes in

the cleats, and screw them in

place, as shown in Photo A.

6 Cut the bottom (K), dust-chute

pieces (L, M, N), and support (O)

to size from MDF. For a tight fit,

miter-cut one edge of part L and

one end of each D.

7 Glue and clamp the basic

cabinet assembly (A, B, K, O)

together in the configuration

shown on Drawing 2 on the

following page. Check for square.

Then, drill the countersunk holes,

and screw the dust-chute pieces (L,

M, N) in place.

8 Working on the outside of the

cabinet, sand the joints between

the two side panels (A) and back

panel (B) smooth. Then, rout a fi"

round-over along the back corners

of the cabinet, starting 4¤" from

the bottom ends, Page 3.

20fi"

35"

All cleats mountedwith #8 x 1‹" F.H.

wood screws

¸" shank hole,countersunk

¤" chamfer alonginside and outsideedges of hole

#8 x 1‹" F.H.wood screw

Hole to fit yourvacuum hose

19"

35"

Router-cordaccess notch

Location of

A

R

A

B

D

F

E

G

J

I

J

H

fi" round-over along backcorners of the cabinet,starting 4¤" frombottom end

C

Location of

A

Location of O

K

3"

› x ›" notch

7"

15fi"

7Á"

1fi"

5Œ"

13Å"

18‹"

*‡"

12fi"

35"

17fi"

19"‡" ‡"

26"

45°

17‡"

7Í"

Å"

A

CD

H

L

F

E

I

*Note: If your materialfor part is a full ‡",allow more than shownfor clearance.

P

Vacuumhose hole

Mitered end

M

N

G

K

O

AA

1 CABINET1a SIDE PANEL(Left-hand panel shown)

Mark the cleat locations, drill themounting holes, and screw thecleats in place on the cabinet sides.

TM

FILENAME Tilt T 2

#8 x 1‹" F.H. wood screws

4"

35"

18Œ"

30Œ"

20fi"

Plate formagneticcatch

Magnetic catch

1fi" continuous hinge19" long

ˇ" and ¨" holes‡" deep forrouter bits

Magnetic catch

To router

Power switch

Cabinet hinge(4" from top andbottom edges)

3fi" wire pull2" from sideedge of door

fi" round-overs

3fi"

fi"round-over

ˇ" and¨" holes forrouter bits

22"#8 x 1‹" F.H.wood screw fi" round-over

18¤"

3fi" wire pull fi" fromfront edge, centered

› x ›" notch forrouter cord 3" fromfront edge

‹" hole fi" deep

‹-20 x 1fi" bolt cut to 1¤" long(Stops with table in full upright position.)

fi" rabbet ›" deep

Plastic laminate on topand bottom surfaces

„" chamfers

Dado to fitmiter gauge‹-20 threaded insert

Use ‹" T-nut on bottomside, epoxy in place.

Router

› x 11‡ x 11‡" phenolic router plate

‹-20 x 1fi" F.H. machine screw

ˇ" hole, countersunk

1fi"-diam. hole, centered

Miteredcorner

¸" hole,countersunk

T

K

T

N

L

B

M

A

A

O

R

T

S

VU

W

Q

P

1¤" glideinto edgeof A

fi" round-over

Note: MDF is dense and requires 7⁄64" pilot holes for #8 x 1‹" F.H. wood screws.

Router wrench

R=1"

T

W

Y

‹-20 x 1fi" F.H. machine screw

Four-arm knobwith ‹" insert

‹" flat washer

fi" round-over

‡"

fi" hole „" deep with a›" hole 1‹" deep centered inside

¸" hole,countersunk

#8 x 1fi" F.H.wood screw

R=1fi"

‡ x 3 x 27‡"

X

Z

Z

2 EXPLODED VIEW

PPage 3 of 12

TM

Page 4 of 12

Add the shelf, door,and base trim1 Cut the router-bit shelf (P) and

small-bit holder (Q) to size.

Locating the holes to properly

space your particular bits, mark

the centerpoints, and then drill

holes in the shelf for your large-

diameter bits. Now drill holes in

the bit holder (Q) for your small

bits. The small-bit holder works

great for straight bits, which

would fall through the holes in

the shelf (P). Next, glue and

clamp the bit holder to the shelf.

2 Cut the base-trim support

piece (R) to the size listed, and

screw it to the front of the

cabinet.

3 Cut the door (S) to the size

shown in Drawing 2. Rout a fi"

round-over along the sides (not

the top and bottom) of the door.

4 Drill holes in the door for

attaching the wire pull later.

5 Attach the hinges where

dimensioned, and mount the door

to the cabinet. Add the magnetic

catches and strike plates to the

door and cabinet.

6 Cut the base-trim pieces (T) to

size plus 1" in length from solid

stock. Rout a fi" round-over along

the top outside edge of each trim

piece. Miter-cut the trim pieces to

length. Working from the inside

of the cabinet, drill countersunk

mounting holes, and then glue

and 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 topNote: On this project, we give youthe option of two different tabletops.The instructions below detailbuilding the 28" square standardtop. You’ll also find dimensions forthe larger 28×36" table, shown inPhoto C on Page 11, that’sdesigned to work with an Incra JigUltra.

1 Cut two pieces of ‡" MDF to

29" square for the tabletop (U),

shown in Drawing 3, and detailed

in Drawings 6 and 7.

2 Glue and clamp the two pieces

together face-to-face. To achieve

uniform clamping pressure in the

center of the lamination, drill

several pilot holes from what will

become the underside of the

tabletop, and then drive several

#8×1‹" screws into the upper

lamination. Next, using clamps

along the edges, secure the two

pieces tightly together until the

glue dries. Now remove all the

screws so you won’t hit them in

the 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 plastic

laminate to 30" square. Apply

contact cement to all mating

surfaces, and adhere the laminate

to both surfaces of the tabletop

(U). Use a rubber roller to ensure

a good bond between the

laminate and MDF.

5 Using a trimming bit, rout the

edges of the laminate flush with the

edges of the tabletop as shown in

Photo B.

6 Cut or rout a dado in the top

(U), where dimensioned, to form

a slot that fits your miter-gauge

guide bar.

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

BB

TM

Page 5 of 12

7¤" Hinge

9"

3‡"

‹" prongless T-nut

LW

O

S

1fi"

‹-20 x 1fi" F.H. machine screw

VU

‹-20 threaded insert

3 SIDE SECTION VIEW

TM

Page 6 of 12

4 FORM THE ROUTER-PLATE RECESS

Centeredside-to-side

11‡ x 11‡"router plate

5"

FR

ON

T E

DG

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

FR

ON

T E

DG

E

Guide

board 2

Guide board 1

Guide board 3

Guide board 4

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

FR

ON

T E

DG

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.

TM

Page 7 of 12

Cut the table insert into the topNote: We secured the router plate to the tabletop withscrews and T-nuts so that the plate (with the routerattached) can’t fall out when tipping the tabletop back.See the Buying Guide for our source for the router plateand hardware.1 The router plate we used (see the Buying Guide)

is listed as a 12"-square plate, but actually measured a

bit less. Using a tablesaw, cut adjoining edges to

square up the plate, then trim it to 11‡" square.

2 Follow the seven-steps, described in Drawing 4, to

form the router-plate recess in the top (U).

3 Mark the centerpoints, and then drill ˇ" holes in

the corners of the router plate, where dimensioned in

Drawing 7. Fit the router plate in the recess, and use

the holes as guides to drill through the corners of the

recess in the top (U).

4 Using epoxy, adhere a ‹" prongless T-nut into

each 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 the

holes in your baseplate as guides, mark and drill

corresponding holes in the router plate.

Countersink or counterbore the holes, as required

for your router, and then mount your router to the

router plate. Place the router and router plate into

the 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

TM

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 view

R=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 ULTRAMOUNTING 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‹"

‡"

‡"

TM

Page 10 of 12

Dado to fitmiter gauge.

FRONT OF TABLE

3‹" 5"

36"

28"R=1"

V

1‹"-diam.plastic knob

Mounting plateIncra Jig Ultra

‡"

3‡"

ALocations of partsLocation 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 systemNote: In addition to the accurate,easy-to-build fence shown, wedesigned this router tabletop to becompatible with a number of fencesystems, including the Incra JigUltra, below right. Before installinganother brand fence, check them a n u f a c t u r e r ’ s m o u n t i n grequirements. 1 Cut the fence (X), base (Y),

and braces (Z) to the sizes listed

in the Materials List and shown

in Drawing 8 on Page 9. Cut the

mounting slots in the base (Y),

where shown.

2 Lay out and cut the 1"-radius bit-

clearance openings in the fence

and base. Now glue and screw

these parts together, and add the

braces to form the completed

fence assembly.

3 Mark the centerpoints for the

threaded inserts on the router top

(U) where dimensioned in

Drawing 6a on Page 8.

4 Drill a fi" hole at each marked

centerpoint just through the

laminate („" deep). (We used a

Forstner 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 on Drawings 10, 11,and 12.)

5 Double-nut a bolt, and use it to

drive a threaded insert into each

hole.

Now attach the tabletopsupport1 From ‡" maple, drill the holes

and cut the pivot block (V) to

shape, as dimensioned in Drawing9 on Page 9.

2 Transfer the support bar (W)

pattern from Drawing 13 to ‹×1"

aluminum bar stock. Cut the piece

to shape, and drill a hole through

one end, where marked.

3 Drill pilot holes, and glue and

screw the pivot block (V) to the

bottom of the router top, where

shown on Drawing 5. Then, attach

the support bar to the pivot block.

Finishing and final assembly1 Remove the router plate and

router from the router tabletop.

Separate the top from the base

cabinet. Remove the hardware,

and sand the cabinet and tabletop

edges smooth. Fill any

imperfections and finish-sand.

2 Prime the base cabinet. (We did

this in several coats, using a

sanding block with 220-grit

sandpaper between coats to

smooth the primer.) Paint the base

cabinet as desired. Apply a clear

finish to edges of the router

tabletop.

3 Hinge the router top and door

to the cabinet. Reattach the

magnetic catches and pulls. Then,

reattach the router with attached

plate to the router tabletop.

4 Attach the fence system of your

choice. Attach a power switch to

the 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 KemmetProject design: Jim DowningIllustrations: Roxanne LeMoine; LornaJohnsonPhotographs: HetheringtonPhotography

‡ 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" MapleX Z

Cutting Diagram

Page 11 of 12

CC

TM

Page 12 of 12

*Parts initially cut oversize. See the

instructions.

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 mounting

screws, ‹-20×1fi" flathead machine

screws (6), ‹" flat washers (2), ‹"

prongless T-nuts (4), power switch, one

pair of cabinet hinges (we used Amerock

#BP-5988-M26), 1¤" glides (4), 3fi" wire

pulls (2), pair of magnetic catches and

strike plates, plastic laminate, contact

cement, ‹-20 threaded inserts (4), four-

arm knobs (2), ‹–20×1fi" bolt trimmed to

1¤" long, ‹×1" aluminum bar stock for

support bar (part W), primer, paint, and

clear finish.

Buying GuideTilt-top router-table kit. The kit

contains everything noted in the Supplies

listing 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 are

available. For more information, contact

Incra 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 1

L 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 1

S 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

CabinetBill of Materials

Matl. Qty*.T W L

FINISHED SIZE

Router Table

Fence

http://www.woodmall.com

®

Thanks for your order!Now that you've got a detailed plan tobuild that perfect project, visit the WOODMALL for the internet's largest source forwoodworking tools and accessories. The WOOD MALL offers:

• Over two dozen woodworking-related stores• More than 50,000 tools & accessories• 24-Hour shopping• Special sales & closeouts• Nearly 40 tool comparison charts• FREE monthly woodworking seminar

Visit Today! http://www.woodmall.com

Like no other magazine, WOOD helps you make the most of your shop time ...takes your skills to the next level. Every issue of WOOD is jam-packed with ...

• Smart tips, tricks, secrets and shortcuts that save you time, effort and money • Valuable tool reviews with at-a-glance information charts that give you helpfulproduct comparisons • Giant full-size pattern pull-outs • Crystal-clear step-by-step instructions, exploded diagrams, finishing secrets and techniques for that pro-fessional look – everything you need to bring out your woodworking genius!

2 years (14 issues) just $44 SAVE $39.30 off single-copy rate!1 year (7 issues) just $26 SAVE $15.65 off single-copy rate!Payment Enclosed Bill Me

My Name (please print)_____________________________________________________

Address ______________________________________ Apt. #__________________

City____________________________ State _________ Zip____________________

Canadian Orders: Fill in the form above. Your rate will be 1 year (7 issues) for $41 – SAVE $14.65, or 2 years (14 issues) for $67 – SAVE$44.30. Prices include postage; 7% GST or 15% HST is added. #12348 2887 RT

U.S. and Canadian subscribers: You also may order by credit card. Call toll free 1-800-374-9663 weekdays from 7 a.m. to 10 p.m. CentralTime; Saturdays, 8 a.m. to 3 p.m.; Sundays, 9 a.m. to 3 p.m.

Other International Orders: 2 years for $89 U.S. or 1 year for $49 U.S.; prices include postage. To order by credit card call 515/246-6952during the same hours as listed above (toll charged). Or complete this form; mail with US funds to: WOOD® Magazine, P.O. Box 37439,Boone, IA. 50037-0439 USA.

Your Money-Back Guarantee: You must be satisfied with your subscription oryou can get a refund for all unmailed issues.

WOOD® Magazine is published 7 times a year. Savings are based on $5.95 U.S., $7.95 Canadian single-copy rate. The first issue mails in 8-12 weeks. Subscription prices subject to change. 4HMF

Fill out information below and mail to: WOOD® Magazine P.O. BOX 37439, Boone, IA. 50037-0439or Subscribe Online at http://www.woodmagazine.com/subscript

Current issue not shown