A few days ago I posted a new video on how to build a router table for my new mobile workbench. Since some of you have asked for specific information about the router insert plate, I’ve decided to post this in-depth article on the topic.

Router Table Plans

 

Router Table Insert Plate Specs

Homemade-router-table-mounting-plate-plans

The insert measures 250 x 200 x 10mm. I’ve made it with a HPL panel, but it could also be made out of aluminum or any plastic board that is tough and thick enough, around 10 mm.

This is the 3D model included in the plans that you will find on my website. If you are interested in collaborating with my web or building your own router insert plate, here you can download them.

How-make-router-table-insert-plate

You can also buy the insert—they’re very easy to find nowadays, and also pretty affordable.

 

How to build a Router Table Insert Plate

How-build-homemade-router-table-insert-plate-jig

I’ve marked the exact position of the router insert on the benchtop. I drill some holes so that I can insert the jig saw blade and make the necessary cuts. I’ll cut 2mm short of the line and later finish cutting the recess with a router.

Now I’ll cut the piece that I will use as router insert. I’ll use the insert I’ve just cut to fine-tune the adjustable router template guide.

Router-insert-plate-flush-trim-bit-diy

Router-bosch-insert-plate-jig-diy

I place it on the table and finish the recess for the insert with the router and a flush trim router bit.

How-make-your-own-router-insert-plate

These are the pieces that will secure the insert to the table. I screw them to the table and glue another 9mm piece of plywood for some added thickness.

How-screw-router-insert-plate-worktable

I mark each of their positions and drill new holes: some are for the threaded inserts and the others are for the screws that will make it possible to regulate the height of the insert. For the latter, I’ll use a bit whose diameter is 0.5mm smaller than the screws I’ll be using, in this case, a 5mm bit.

I’ll use a bolt with its head cut off to mark on the insert plate the exact position of the screws that will fix it to the table. Once these are made, I screw the table back onto the bench one last time, by inserting all of the screws.

router-insert-plate-printable-template-diy-plans

It’s time to mark and drill the necessary holes in the insert so that we can fasten the router fixed base. I’ll also make a hole that will act as a rotation axis to cut a recess for the insert rings.

I’ve attached the circle cutting jig to the plunge router, and before anything else, I run a test with a piece of MDF to make sure the diameter is correct.

The first cut will be about 5mm deep, half the thickness of the insert. The second one will be 5mm further toward the center, cutting completely through. I make sure everything is correct by screwing the fixed base to the insert; and it seems that it is.

I’ve glued the printable template, pulling it back 15mm. I’m doing this because in the future I want to make a new and improved router lift, and I’m probably going to need some more space on the front of the insert to insert a screw that will make it possible to lift and lower the router.

Router-table-insert-plate-bench-saw-plans

The worktable of the router measures about 570 x 560mm. As you can see, this design has a folding extension in the back of the bench that will provide me with a much larger worktable for milling big pieces.

If you want to see how I made the insert rings to use with this insert plate here you will find the article.

 

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