Homemade Router & Saw Table

08/20/2015 20:22:32   Categories: DIY Tools , Saws

A versatile, easy-to-make Router and Saw table for small workshops. It includes all kinds of custom accessories that make work easier. It also has a space to keep all these accessories organized and handy. Here you'll find the plans.

The machine is made with birch and okume plywood. The birch is for the parts which need to be resistant and the ocume is for the rest, making the total weight lighter.

The cover is made of birch plywood with melamine on both faces, although another similar material may be used. It has grooves which act as cutting guides, featuring an aluminium U profile in order to improve sliding.

The bodywork is made of ocume plywood put together with screws and dowels. I have not used glue in case I have to dismantle or redesign it one day. For the joints of the bodywork I have used 4x50 screws.

The bodywork is strengthened with two strips of hard wood, to which I screwed in adjustable legs. I have applied two coats of lacquer in order to protect it and give it longevity; it all depends on the material which is used. As for dust removal, a bag vacuum cleaner with a 100mm tube is ideal.

We attach the tube to the side of the machine. It then forks into two 50mm tubes, one going directly to the outlet of the circular saw and the other to the empty space of the machine.

You could also send the cutting list included in the plans to a carpentry warehouse. They will cut and reference all the pieces, so you will only have to machine the smaller cuts and put the pieces together.

These designs are for my original saw & router table, for routers with 43mm clamping collar and a Makita 5903R circular saw. For other tools, you will most likely to modify the plans a little.

Approximate weight: 45kg

Total dimensions: 900mm High, 1260mm Wide and 1000mm Long.

As you can see in the video, the cover -which doubles as a table- is made of 20mm birch plywood with melamine on both faces. I found this in a carpenter’s shop, but I don’t remember what it had originally been used for. However, when I saw it, I didn't hesitate to buy it, as these are difficult to find for small scale production purposes.

Normal, varnished birch would do the job perfectly, and that was my first idea. It is screwed underneath the main body and has recesses for a saw and a milling machine, some on the top in order to make it easier to change the disks and cutters, others on the underside in order to attach the saw to the table and achieve a deeper cut. It has other recesses on the top to insert the aluminium profile which will act as a guide.

I machined all these recesses with a router and guides. This part is very important in order to achieve perfect cuts. All the templates for this milling must be placed straight and in perfect alignment.

You could also use a T-track profile, like I did in my portable workshop. My profile measures 15mm wide by 10mm deep, but other measurements can be used, but only up to 10mm depth to avoid compromising the stability of the table. The profile must fit tightly but not so much that it has to be forced in.

The support for the horizontal router is made of birch plywood and must be hard and stable to support the weight of the router itself. The part in contact with the router is 20mm, the rest is 12mm. You must ensure all the work pieces are perfectly aligned when you cut them if you want the router to cut properly.

It is meant for routers with a 43mm clamping collar, be very precise when making this hole. If you overdo it, the router will be loose, which is obviously a hazard!

For do that I have used an adjustable drill. Also I have ud¡sed 8mm metric bolts with threaded inserts.

The vertical support for the router is made of birch and okumen, although you could make it with just birch. Again, I've used a 43mm clamping collar for greater versatility. Also here I have used an adjustable drill. The tightening handles are made of birch plywood and I used metric 8 with their corresponding threaded inserts.

Check the length of your router in case the structure is too short and you have to lengthen it a little. The hinges enable you to turn the router and make the most of its possibilities to make mouldings or cuts. Use glue and long screws to make the support sturdier.

I have developed this template in order to make box and drawer joints more easily and comfortably. Make an MDF template with outlets and inlets every 10mm. I have made these on my homemade Cnc router, but if you do not have one, you should order these templates from someone who does. It is very important that these are perfect so that the system will work correctly.

You can also make it without Cnc like the one I used in my portable workshop, here you can see it in action.

In order to use it, as can be seen in the video, you must place each workpiece touching each end, with one beginning at an inlet and the other at an outlet with the same measurements as the gaps of each recess. 

In this video, it is possible to see how the table router and table saw work. I begin the 3D Router project with my circular saw. Assembling this tool requires extreme precision and extensive experience in carpentry work.

The cuts must be perfectly straight, the axes must be perfectly parallel so that the ball bearings do not have any backlash, and are correctly aligned, if this is not the case, there will be vibrations which will be transferred to the output. A 43mm clamping collar makes it very versatile and you can change the milling tool to drill very fast. 

Update (22/12/2015)

The home vacuum I've been using wasn't powerful enough to collect all the dust and shavings so I decided to connect a suction pipe from my saw table to my new dust collector. It works amazingly well!

Some of you have asked me whether it would be possible to adapt the Inverted Jig Saw Guide of my Portable Workshop to the Router & Saw Table. And the answer is yes! It can be adapted to those or any other table or workbenches you might have at home.

Where to get some materials and tools used in this project:

Visit the Router & Saw Table Topic in Forum:

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View all comments (22)

05/29/2018 01:02:28


Hola de que material son las guias deslizantes (en la mesa son de aluminio) y en el carro son de madera dura parece que madera es? Gracias saludos

04/30/2018 06:44:50

Ronald Rowlands

I just love woodworking and YouTube you come across the most wonderful people from all over the World ,

03/06/2018 08:28:46


Cual sierra estás usando en esa mesa? Se puede usar la makita sp6000 para este proyecto? Un saludo desde Suiza.

10/17/2017 10:24:49

Suso Caamanho

hi Jens, that's Hpl panel

10/15/2017 20:17:29

Jens Christian Nørtoft Bækgaard

Hello I have a question: For the miter-slots you use a alu-U-profile. But what is the slider on the bottom of the cross cut sled made of? Is it hard wood? Metal? or something else?Thanks in advance. Greetings from Denmark

10/08/2017 17:23:48


Wath is it the dimension table saw? Thank you

11/10/2016 17:33:34


What's the approximate cost of materials to build the unit? I am budget conscious.

10/09/2016 12:58:13

artigianato e fai da te

Very interesting site, from Italy, congrats!

05/26/2016 09:16:18


Hola Ser,sí, puedes encontralos aquí: http://paoson.com/

05/26/2016 03:44:12


Buenas. Los felicito por la página y todos estas obras... de arte. Quería saber si tienen a la venta la mesa casera de sierra y fresadora. Gracias

05/21/2016 21:56:42

Paoson Woodworking

yes Mike, all the attachments are inclued!

05/20/2016 23:55:00


Hello. Does the plan include all the attachments that you show in the video? Thank you

05/20/2016 10:05:30

Paoson Woodworking

Obrigado Everaldo Seckler! bom blogue

05/19/2016 19:40:06

Everaldo Seckler

Paoson, um dos projetos mais completos que tive o prazer de conhecer, meus parabéns pelas ideias e pela execução. Gostei demais, que até postei o link em meu blog: Ah! E se falando em Madeira... - eseck1.blogspot.com.br - Agradeço ter disposto todas as informações e videos da construção. Um abraço desde: Porto Alegre - Rio Grande do Sul - Brasil Do, agora em diante, seu amigo Everaldo.

05/18/2016 10:14:57


Hi Martin,you can find the plans here: http://paoson.com/

05/17/2016 12:16:08


I would like to ask if I can have the plans for this fantastic piece. Thank you very much My email: [email protected]

02/10/2016 14:14:13


Thanks Alan,I am preparing a video for my portable Workshop where I will try to show a closer look. Stay tuned!

02/10/2016 14:03:53

Alan Rogers

Is it possible please to get a closer look at your finger joint jig? I've seen lots online and some of them are fantastic, but not necessarily in a good way. Yours looks incredibly simple, works with the cross cut sled, and probably the router too, and I like the way in which you've got different sized joint jigs on each edge of the same piece of wood. Unfortunately, the jig only gets a walk-on part in your video!Thanks in advanceAlan

12/17/2015 15:33:14

Suso from Paoson

Thanks friends!

12/17/2015 15:31:31


esta buenísima la mesa multi usos me gusta para mi taller y tener todo mas a la mano y limpo

12/17/2015 13:43:32


Awesome Design, Awesome Build

11/23/2015 10:21:11


Nice configuration.

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