In this detailed guide, we will walk you through the steps to create Norm Abram’s classic router station. This project features enhanced storage, a more stable fence, and upgraded electrical connections, making it a versatile addition to any workshop.
Gather Materials and Tools
Before you start building, ensure you have the following materials and tools ready:
- Materials:
- Half-inch MDF
- Three-quarter-inch MDF
- Oak for trimming
- High pressure laminate
- Plexiglass panel
- Drawer slides
- Polyurethane glue
- Wood screws
- Dust collection components (PVC pipes, plumbing tee)
- Tools:
- Table saw
- Router with appropriate bits
- Drill
- Clamps
- J roller
- Dado set
- Tapering jig
Preparing the Top Section
Start by cutting your MDF sheets to size. The top should have grooves for the miter gauge track, slots for the fence, and a hole for the router plate. Remember to pre-drill holes to avoid splitting the MDF when you attach the pieces together. Apply glue, align the pieces, and use clamps to hold everything in place while the glue dries.
Mitering and Biscuit Joinery
Next, you will miter the edges of the oak trim that will secure the MDF top. Lay out biscuit slots every eight to ten inches to reinforce the joints. Apply glue in the slots and clamp the pieces together to ensure a strong bond. This method not only strengthens the assembly but also provides a seamless finish.
Constructing the Fence
The fence is a critical component of the router station. Begin by cutting out the necessary shapes from MDF and chamfering the edges to allow for better dust flow. Pre-drill for screws to prevent splitting, then assemble the vertical and horizontal pieces using glue and screws. Add braces to maintain the fence’s square shape.
Attaching High Pressure Laminate
Once the fence is assembled, it’s time to attach the high pressure laminate to the countertop. Apply glue to both the laminate and the MDF surface. Once tacky, carefully align and press them together using a j roller to eliminate air bubbles. Trim any excess laminate to achieve a flush finish with a flush cutting bit.
Cutting Slots for T-Bolts and Router Plate
In this step, we will create the necessary slots for the T-bolts and the router plate. This is crucial for securing the fence and allowing for easy adjustments. Start by measuring and marking where the slots will be located on the MDF top. Using a router, cut a wider slot for the T-bolt head, followed by a narrower slot for the threaded part of the bolt. This ensures that when you tighten the fence, it will stay securely in place without any spinning.
Next, we will cut out the hole for the router plate. This hole needs to be precise, so take your time. Create a template that is slightly larger than the router plate itself to accommodate for the collar. Once the template is ready, use it to guide your router bit for a clean and accurate cut. This step is essential for ensuring that the router fits snugly into the top, providing stability during use.
Building the Cabinet Base
Now that the top section is prepared, it’s time to focus on the cabinet base. The base is constructed from three-quarter-inch plywood panels. Begin by cutting the panels according to the provided dimensions. Make sure to include dados and rabbets for shelf supports and drawer runners; these will provide additional strength and stability to the structure.
Assemble the base using glue and screws. When installing the runners for the drawers, ensure they are level and properly aligned. This will allow the drawers to slide in and out smoothly. Once the base is complete, you can add partitions to create separate spaces for the drawers, maximizing your storage capabilities.
Setting Up Dust Collection
Effective dust collection is essential for maintaining a clean workspace. For this router station, you will need to set up a dust collection system that can effectively capture debris from both the router and the cabinet. Start by drilling a hole in the back of the cabinet to accommodate the dust collection pipe.
Install a plumbing tee to connect the dust collector to the cabinet. Ensure that the slope of the internal plywood directs dust and chips towards the pipe, preventing clogging. This setup will help keep your workspace tidy and allow for better visibility while working.
Assembling the Drawers and Doors
With the cabinet base complete, it’s time to focus on the drawers and doors. For the drawers, use quarter-inch plywood for the bottoms and ensure that all sides have grooves to receive them. Assemble the drawers using a mix of polyurethane glue and carpenter’s glue for added strength.
For the door, create an oak frame that is mitered at the corners, with a groove to receive the plexiglass panel. This design not only provides access but also adds a modern touch to your router station. Once the door is assembled, install it with a hinge for easy access to the router compartment.
Installing Electrical Components
As you approach the final stages of assembly, it’s crucial to install the electrical components safely. Start by mounting a surface-mounted switch that is easily accessible from the front of the cabinet. Ensure that all electrical connections are secure and that wires are properly routed to avoid any interference with the drawers or doors.
Separate the electrical components from the bit storage areas to ensure safety. A shelf can be used to keep electrics away from any dust and debris. Finally, verify that the switch operates smoothly and that all wiring is neatly organized.
Final Assembly and Testing
With all components assembled, it’s time for the final assembly. Secure the top to the base using screws, but do not permanently attach it; this allows for future access if needed. Plug in your router and drop it into the cabinet, ensuring it is positioned correctly.
Once everything is in place, conduct a thorough test of the router station. Check the dust collection efficiency, and ensure that all drawers open smoothly. Adjust any components as necessary to achieve the best performance. With everything tested and in working order, your custom router station is ready for action!
Congratulations! You’ve successfully built Norm Abram’s router station. This project not only enhances your workshop’s functionality but also provides a dedicated space for your router and accessories.