This project was built and designed by Norm Abram from The New Yankee Workshop. It’s a redesigned version of his classic router station, enhanced with thoughtful updates to improve organization, dust collection, and usability.
The updated design offers a cleaner workflow, more durable materials, and simplified features that woodworkers of all levels can appreciate. It’s a shop essential that balances precision, functionality, and smart construction.
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Why Upgrade the Router Station?
Norm’s original router station has been a favorite in the woodworking world for decades. Many have followed his build plans to add it to their own workshops, but over time, certain features needed improvement.
This deluxe version introduces several updates to make the tool more practical for modern use. These upgrades focus on storage efficiency, improved dust management, and easier material sourcing—all while preserving the integrity of the original design.
Key Enhancements to the New Design
One of the most noticeable changes is the storage layout. The drawer system has been reorganized to hold more tools and bits in a more structured way. Larger accessories now have a dedicated deep drawer, while two upper drawers keep smaller items accessible and organized.
Dust collection has also been upgraded with a more efficient setup inside the cabinet. A sloped internal panel funnels debris directly into a vacuum system, reducing airborne particles and improving visibility while working.
The fence has been redesigned for easier adjustment and long-term durability. Using stable materials helps avoid warping, and pre-drilled slots make the setup more precise.
Another smart change is the replacement of the original switch with a more affordable and easily sourced option. This update makes maintenance simpler and lowers the barrier for other woodworkers to replicate the build.
Finally, the router station top now uses laminated MDF and high-pressure laminate—materials that are easy to find at home improvement stores. These layers create a stable, durable surface that resists wear over time.
Constructing the Table Top
The build starts with layering half-inch and three-quarter-inch MDF to create a rigid, vibration-resistant top. After cutting both panels to size, glue is applied and the pieces are clamped to cure evenly.
Once the top is dry, oak trim is added for edge protection and appearance. Biscuit slots are used to secure the trim pieces, strengthening the bond and helping the trim stay flush with the MDF.
A router plate hole, miter track grooves, and fence slots are carefully measured and cut into the top. This layout ensures compatibility with common accessories and gives the table flexibility for a range of routing tasks.
Building the Fence System
The fence uses a vertical and horizontal combination of MDF parts with dedicated openings for chip ejection. This helps improve dust control and keeps the cutting path visible.
Holes are pre-drilled for screws to prevent splitting, and glue is added to reinforce the joints. Once assembled, additional braces are added to keep the fence square and secure through repeated use.
The design also allows for easy repositioning of the fence when changing bits or setups, improving workflow during complex routing tasks.
Efficient Dust Collection
A sloped plywood panel is installed inside the cabinet to guide dust and chips directly toward the vacuum connection. This passive setup minimizes cleanup and helps prevent buildup around the router.
By keeping both the tabletop and cabinet clean during use, this system extends the life of the router and improves accuracy by reducing debris interference.
Organizing Router Bits and Tools
Drawers are built from plywood with quarter-inch grooves for solid bottoms. They’re measured to fit various router bit sizes, accessories, and tools that often clutter shop surfaces.
Full extension drawer slides allow easy access to every part of the drawer, even when loaded. This not only improves convenience but also reduces the chance of tipping or spillage during use.
The layout is modular enough to accommodate changes as the tool collection grows, keeping the storage system adaptable over time.
Wiring and Final Setup
The router station includes a mounted switch located for quick access during routing. The wiring is routed away from the storage drawers to avoid interference and maintain safe operation.
Final steps include testing all moving parts, checking drawer fit, verifying fence alignment, and ensuring the router plate sits flush in the table. Once confirmed, the router is installed and ready for shop use.
A Practical Upgrade for Serious Woodworkers
Norm Abram’s deluxe router station is a well-thought-out revision of a proven classic. Each modification is aimed at solving real issues woodworkers encounter with storage, dust, and usability.
By using accessible materials and streamlined joinery techniques, this project remains practical for DIYers while offering professional-level performance. It’s a valuable addition to any shop setup.
You can get the plans here: https://www.newyankee.com/episode/deluxe-router-station/.