Replies

1. 
   gweisenburge | Nov 07, 2002 09:21pm | #1

   Matt,

   1/4-inch hardboard is too flimsy. I prefer 1/4-inch aluminum. You can cut and drill it with woodworking tools. I've also used 1/4-inch Lexan.

   Gary

1. 
   DWRead | Nov 08, 2002 05:36am | #2

   The local lumberyard has plastic laminate, 1/32" thick. But I'd have to buy a whole sheet, at $45! Is there another low-friction material that could be used for inserts?

1. 
   PlaneWood | Nov 08, 2002 07:57am | #3

   I bought 3 pieces of aluminum (12"x12"x1/4") on Ebay for about $15 total, including shipping!  Cut it to shape with a fine tooth blade on my bandsaw.   Cut the center hole with a hole saw using my drill press.  Works great!

   PlaneWood by Mike_in_KatyPlaneWood

2. 
   gweisenburge | Nov 09, 2002 04:30am | #6

   DW,

   What are you planning to do with the 1/32-in-thick pastic laminate? I'd use it on the tabletop, but I wouldn't laminate it onto the router base insert. The insert should be stiff, like aluminum, Lexan, or polycarbonate, and it shouldn't be more than 1/4-inch thick. That's the thickness of standard, plastic, factory bases. More than that and you begin to lose depth of cut; less and you lose stiffness.  You can make most any material's surface slippery with wax. 

1. 
   DWRead | Nov 09, 2002 04:40am | #7

   The plastic was supposed to be for a primitive router "table"--just the table top, actually--that I made last week out of 3/4" plywood. The table is functional as is, but I found three projects that use plastic laminate in router tables:

   Plastic laminate glued to plywood ("Benchtop router table," WOOD,  December 2001, pp 44-49)

   Zero-clearance insert (http://www.woodworkingtips.com/woodtips/wbtip07.html)

   MDF covered with Formica or Melamine (http://www.dewalt.com/us/articles/article.asp?Site=woodworking&ID=201)

   My tablesaw requires a very thin insert, and I figured that plastic wouldn't split the way plywood does.

   Janet

   Edited 11/8/2002 9:08:13 PM ET by DWREAD

2. 
   RickL750 | Nov 08, 2002 03:53pm | #4

   Matt,

   I use polycarbonate, lexan, or acrylic it’s clear, rigid enough if you by 3/8” thick or better and poly is shatter proof. As far as cutting or drilling you can use regular tools, you can buy a piece of 12”x12” for about $15 dollars from any woodworking store, sign shop, or catalog. In my case I use a square piece about one inch larger than my router as my regular baseplate with holes drilled on each corner that allows me to attach to my table easily.

    RickL

   
   

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   Edited 11/8/2002 12:49:34 PM ET by RickL

3. 
   RANGERP75R | Nov 09, 2002 04:01am | #5

   Matt

      The aluminum is great. I use the phenolic and have used Lexan. Avoid the hard-board. To flimsy.

   Good Luck..

   sarge..jt