This project was built and designed by Rob from Let’s Make Things. It’s a straightforward yet highly functional router fence that improves accuracy, safety, and versatility when working with a router table or table saw extension.
Rob focuses on practicality and ease of construction, using plywood, T-tracks, and smart layout choices to create a fence that’s adaptable to various router bit sizes and cutting operations. The result is a shop upgrade that’s well within reach of any skill level.
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A Smart and Accessible Upgrade
A router fence is one of the most helpful accessories for routing, especially when working with dados, edge profiles, or joinery. Rob’s version is built from simple materials but packed with useful features, including adjustable fences, dust collection, and profile-bit support.
What makes this build stand out is its flexibility. The fence can be mounted to either a router table or a table saw extension, making it a great addition to small and large shops alike.
Building the Base
The foundation of the fence is a strong plywood base, made up of a flat platform and vertical walls that support the structure. Accuracy during cutting and assembly is key here to ensure a square and stable setup.
Rob uses dados to recess the T-tracks into the plywood. This allows components to sit flush, making adjustments easier and more secure. He marks and cuts the dados using stop blocks for repeatability, ensuring a clean, consistent layout across all parts.
Each piece is assembled carefully to form a tight-fitting base. Getting this part right makes every adjustment easier down the line.
Integrated Dust Collection
Routers create a lot of fine dust, so Rob adds a dust port directly into the back of the fence. This keeps the work area clean and improves visibility during cuts.
To make space for the dust port, he cuts an opening in the base using a bandsaw or hole saw. For those without these tools, Rob suggests alternative methods like using multiple saw cuts and cleaning up the shape with a chisel or rasp.
The dust port is attached with screws and pre-drilled holes to avoid cracking. Its location is optimized to work with both router tables and table saw extensions.
Fence Assembly and Adjustability
The fence itself is built from a plywood panel cut to fit the base. It slides along the T-tracks and can be locked in place using bolts and knobs.
Rob installs T-tracks into the face of the fence, which hold adjustable fence arms that move closer or farther from the bit. This design works especially well when using larger profile bits or when fine-tuning for specific cuts.
Alignment and fit are key at this stage. Rob uses clamps and pre-drilled holes to keep everything square while fastening the components.
Clamping the Fence in Place
Rob demonstrates two clamping options to attach the fence to the table. The first is a simple hole drilled through the side of the base for use with basic clamps.
The second uses a custom fence clamp design from a previous project. While this offers a cleaner look, Rob notes that clamp pressure must be even to avoid lifting or shifting the fence. He shares tips for rounding clamp holes and adjusting pressure points to get a solid hold.
Squaring the Fence
Once mounted, the fence must be squared to the router table or saw surface. Rob checks for gaps using a carpenter’s square and corrects any misalignment with thin shims behind the fence face.
This step may seem minor but has a major impact on cut accuracy, especially for joinery or routing along narrow stock. Getting the fence perfectly square ensures clean, repeatable results.
Safety and Ease of Use
Rob’s fence design offers excellent support and control while routing. The adjustable fence faces help reduce tear-out and keep the workpiece tight to the bit, while the dust port improves safety and visibility.
The design also supports bearing-guided router bits. When routing with a bearing, the fence can be pulled back to allow the stock to ride directly against it, simplifying setup.
Optional Features for More Flexibility
To add even more versatility, Rob includes space for a second T-track on the front of the fence. This track can hold stops or guides, ideal for repetitive cuts or consistent lengths.
He also introduces a removable insert made from hardboard that fits into a cutout in the fence face. This insert can be shaped to match various router bit profiles and swapped out as needed, helping replicate patterns with accuracy.
Rob explains how to cut the insert flush and secure it tightly, making the system modular without compromising precision.
A Practical Upgrade for Your Router Table
Rob’s router fence is a smart, easy-to-build solution that adds a ton of functionality to any woodworking setup. It’s especially helpful for small shops or anyone using a router table extension on a table saw.
With just plywood, T-tracks, and thoughtful layout work, Rob shows how to improve accuracy, safety, and flexibility in one build. The project is beginner-friendly, but the features are advanced enough to be useful for seasoned woodworkers too.
Get Rob’s plans here: https://makethingswithrob.com/make-a-router-fence-for-your-table-saw/.