This project was built and designed by David from dk builds.
It’s a simple and affordable router table extension designed to fit directly into the open wing space of a contractor-style table saw.
For small workshops or shared spaces, maximizing surface area and tool access is key.
David tackled this common issue by converting the unused wing area on his Delta contractor saw into a functional router table—all for around $20 in materials.
Watch the full video and subscribe to David’s channel:
Why a Router Table Extension Makes Sense
Many table saws, especially contractor models, come with space for an extension wing that often goes unused.
David saw this as the perfect opportunity to add a router table, giving him more function without needing additional floor space.
The key benefit of this setup is how seamlessly it integrates into the saw. Instead of building a standalone router table, which takes up valuable shop room, this version keeps everything compact and accessible.
Materials and Cost Breakdown
This project uses primarily ¾-inch plywood, a material known for its strength and stability.
David chose plywood for both the tabletop box and the custom fence, helping keep costs low while still ensuring the router table would hold up to regular use.
Total material costs came in under $20—an impressive number considering commercial router tables often cost several hundred dollars.
For woodworkers on a tight budget or just getting started, this project offers high value at low cost.
Building the Main Extension Box
The router table extension is essentially a shallow plywood box designed to bolt directly onto the saw.
It measures approximately 27 inches long and 19 inches wide, with a height that matches the saw’s table surface.
David begins by cutting the plywood using a circular saw and a guide rail. This ensures clean, straight cuts for the top, bottom, and sides of the box. While perfection isn’t critical, keeping the top surface as level as possible is important for safe routing.
The sides are cut using a crosscut sled for accuracy.
Once the panels are ready, David pre-drills holes in the appropriate locations so the entire box can be bolted to the saw frame for stability.
Mounting the Router and Base Plate
With the box assembled and mounted to the table saw, the next step is installing the router.
David uses a fixed-base router and recesses it slightly into the bottom of the table, allowing for better height adjustment of router bits.
Positioning the router before final box assembly may seem backward, but it simplifies the mounting process.
David’s method shows that even a slightly unconventional approach can work well when the design is forgiving and straightforward.
This setup supports most standard routers and allows for easy bit changes from the top of the table. The recessed design means the router bits can protrude high enough even when not fully raised.
Creating the Custom Router Fence
One of the standout features of this build is the detachable router fence. Inspired by another YouTube maker, David’s fence clamps directly onto the existing table saw fence for easy alignment and adjustment.
The fence includes a cutout for router bits and a removable dust collection port.
This port can be connected to a standard shop vac, making cleanup much easier and helping keep the workspace safe from debris.
The clamping mechanism is simple but effective, and the design allows for fine-tuning based on the bit size or workpiece. It’s a smart way to make the router table more versatile without investing in complicated hardware.
Surface Treatment and Finishing Details
Before calling the project complete, David applies paste wax to the top and fence surfaces.
This small step improves workpiece movement, helps resist moisture, and gives the plywood a clean, finished feel.
Paste wax also reduces friction when feeding wood across the router bit, leading to smoother results and less effort during use. It’s an easy upgrade that adds long-term value to any shop-made work surface.
Final Thoughts and Workshop Benefits
By the end of the day, David’s table saw has been upgraded into a multi-use station with full routing capabilities.
The setup is compact, budget-friendly, and customized exactly to his shop needs.
This project is a great example of how thinking creatively about shop space can lead to powerful upgrades. Instead of spending hundreds on a separate router table, David used simple plywood and a few bolts to create something just as functional.
For woodworkers with limited room or funds, this router table extension is an ideal weekend project.
It improves workflow, expands tool access, and adds functionality without any sacrifice in quality.
Please support David by visiting his Etsy Store and buying his plans.
Matt’s Take
These are my personal thoughts and tips based on my own experience in the shop. This section is not written, reviewed, or endorsed by the original creator of this project.
What I love about David’s approach here is the smart use of dead space. That empty wing area on contractor saws is practically begging for a project like this, and turning it into a router table is brilliant for small shops. The $20 price tag really drives home how much value you can create with basic materials and some thoughtful design.
The paste wax finish is a detail that makes a huge difference in daily use. Router tables see a lot of friction, and that slick surface will make feeding stock so much smoother. It’s one of those small touches that separate a functional project from a truly enjoyable one to use. Plus, the wax helps protect the plywood from moisture and general shop grime.
Safety-wise, having the router table at the same height as your table saw creates a nice large work surface for handling bigger pieces. Just remember that router tables demand respect—always use push sticks or featherboards when your hands would otherwise get too close to the bit. The dust collection port David built in is smart too, since router work can create a lot of fine particles.
This type of integrated setup really maximizes shop efficiency. Instead of shuffling between separate stations, you’ve got routing capability right where you’re already working. For anyone considering this project, take time to ensure everything is square and solid—a wobbly router table isn’t just frustrating, it’s genuinely dangerous.