R4511 Router Table & Fence

[TheChucker]

Today I completed the router table extension for my R4511, and added some new faces to the stock fence.

I replaced the stock rails with some new one piece steel tubes that made mounting the router table possible since you cannot drill into the granite. It's nice having the extra work surface as well and the 40" cut capacity to the right.

When I finished the router table I made a quick zero clearance insert out of some extra mdf I hade laying around. I'm gonna make a few more for my dado blade and other blades as well.

Overall, these upgrades have improved on what is already a fantastic saw.

[toecat]

Looks good. Would you take a picture of the underside of the router table?
Thanks

[chrisexv6]

Nice job! I have the materials just about ready to do this to mine.

Question - whats the finished size of the router extension? Im debating exactly what size I want. Also weighing size vs weight (i.e. will the saw end up "right heavy" if the extension is too large/heavy)

Also, did you upgrade the rear rail? I bought a single piece of angle for the rear rail, but I got it in the stock thickness (1/8").....someone here mentioned it is probably necessary to upgrade to 3/16" thick if adding a router extension. Did you upgrade the thickness?

Thanks.

-Chris

[Saw Dust Maker]

Very Nice!

[TheChucker]

Question - whats the finished size of the router extension? Im debating exactly what size I want. Also weighing size vs weight (i.e. will the saw end up "right heavy" if the extension is too large/heavy)

Also, did you upgrade the rear rail? I bought a single piece of angle for the rear rail, but I got it in the stock thickness (1/8").....someone here mentioned it is probably necessary to upgrade to 3/16" thick if adding a router extension. Did you upgrade the thickness?


The finished size of the router extension is 27" x 30". It runs just about up to the end of the 6' front tube. Making it run to the end of the tube did not add that much weight, and it nice to have extra surface area to work on. I don't feel the saw being right heavy after this at all. There is so much weight centered around the core of the saw with the granite that this extension in my opinion does little to affect it.

I did upgrade the real rail as well. When I was at the steel yard I tested out the 1/8" steel and it didn't flex at all, so I went with that as opposed to the thicker 3/16".

[chrisexv6]

Thanks for the info.

In my version I extend the front rail holder (the angle)........that was the single most expensive piece of material because I didnt have it. now that I see your version, I could have done away with it altogether. Oh well, live and learn!

Hopefully the extra 2.5x2.5 angle iron hanging off the granite wont cause a problem. Im thinking not, Im only adding 24" of it....allmetalsinc.com has the weight listed as 3 lbs/ft, so Im only adding 6 lbs......pretty sure the granite can handle that.

[chrisexv6]

Ive made both my front and rear rails. Now Im looking at which way is best to mount my LS positioner.

Im in a dilemma.......my original intention was to mount it hanging off the right side, to maximize room on the router table. But now I realize that I will never be able to stand "in front" of the router table. Is this a bad thing?

The only other option is to mount it with the rear of the positioner towards the blade, and the only way that will work is if I make sure the blade is lowered and the gaurd is removed. Not necessarily a bad thing, just maybe a pain to setup during use.

I could swear I saw someone with a router extension and LS positioner on it, but cant find pics right now.

[Marshall Goode]

Great looking add on.

I added the router wing to an older craftsman contractor saw several years ago but the stand can't take the weight. It is totally right heavy.

What did you make the table out of? Looks like MDF?

[TheChucker]

Great looking add on.

I added the router wing to an older craftsman contractor saw several years ago but the stand can't take the weight. It is totally right heavy.

What did you make the table out of? Looks like MDF?

The table is made out of a plywood sub structure and the top is 1/4" hardboard over 1" mdf. I like using hardboard b/c it's cheap and it's really slick so the boards just slide across it.

I don't feel the saw is right heavy at all. The saw weighs so much to begin with that the router table does little to effect it.

[chrisexv6]

Any tips on painting the longer fences and rails?

I was thinking of something smooth and durable, like a spray epoxy for appliances (RustOleum, Krylon, etc). If its smooth enough, I dont have to avoid painting where the fence slides.

[Millipede]

If you can find a shop that does powder coating or an auto body shop, those finishes tend to hold up better than spray can paints.

[azwoodwker]

Where did you get the fence tubing? I was also thinking of extending the rails.
Thanks

[TheChucker]

Where did you get the fence tubing? I was also thinking of extending the rails.

I got the rails at a place called Discount Steel. They have a physical location here in Minnesota with the best prices on any kind of steel I could find. I think they're online at www.discountsteel.com (http://www.discountsteel.com). Equally good prices, but the shipping can be quite pricey.

[azwoodwker]

Thanks I will look into it. I was orignally from WI but now live in the heat of AZ

[Sgt Beavis]

For the love of all that is good in the world, show us how you attached it. We need pics.

The only reason I haven't bought this tablesaw is because I didn't believe I could attach a router table wing. I have one on my TS3660 and will only consider a new table saw that lets me do the same..

Here's mine..
http://farm4.static.flickr.com/3474/3355765787_1b10c35204_b.jpg

[chrisexv6]

I dont have any pics, but I made the rails one piece in front and back, and added a few extra holes in each rail to bolt a router extension to.

No, there isnt an easy way to bolt the extension to the granite wing, but I figured 3 extra holes in the front and rear rails is plenty of support for the router extension. For a little extra support I was planning on a steel angle under the router extension that goes between the rails of the saw (even considered bolting it to the rails)

It should work fine that way. I changed directions a bit and am sticking with a separate router table, thats why I dont have any pics of my setup.

[Legacy Woodcraft]

I also attached a router table extension wing onto my 4511. A limited budget left me searching for materials lying around the shop and things I could get for free at my day job (Metalcasting company).

It is a 3/4" ply under 3/4" MDF covered with 1/8" sheet metal.

I fabricated a frame, which basically looks like "TT" - an angle iron member on the back that attaces to the rear rail with bolts and the two flat iron members that run front to back and are mounted under the front rail. I drilled and tapped the front rail - but had to be very careful as the front rail material is extremely thin and looks to be prone to stripping.

It doesn't have a miter slot, but I'm certain I can make a very large fence for the miter gauge and use it in the slot to the right of the table saw blade.

[DarkWolf]

I also attached a router table extension wing onto my 4511.

Any chance you can slap up some more detailed shots on how the table is affixed to the factory rails?

I'd prefer not to change the rails out.. At least not quite yet.

[CJD18]

Can you tell me what size rails you used?

[coho10]

I just got the 4511 last night. I'd love to get some more information from you guys on how to re-do the front and rear rails on my saw so that I can mount a router table to it.

More pictures of your set ups and details on the materials would be greatly appreciated!

Cory

[DarkWolf]

Followup to requests for more pictures seems to be slim to none.. Soon as I'm done with this fireplace mantel I'll be doing my extension.. I'll be replacing the right wing entirely though, most likely. Make life a little easier, IMO.