Homemade Router & Saw table

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

Dimensions: 1260x1000mm, 900mm height.

A clever Router and Saw table for small workshops, versatile and easy to make. It includes all type of custom accessories that make work easier. It also has a section to save all these accessories organized and handy.

Machine is manufactured with a plywood board made of birch and ocume. Birch for the parts which need to have resistance and ocume 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 and these have an aluminium U profile in order to improve sliding. The bodywork is made of ocume plywood screwed together and with dowels. I have not used glue in case I have to dismantle or rectify it one day. For the joins of the bodywork I have used 4x50 screws.

The bodywork is strengthened with tow strips of hard wood, where I have screwed in adjustable legs. I have applied two coats of lacquer in order to protect it and so that it will last for more years, everything depends on the material which is used. As regards vacuuming, a bag vacuum cleaner with a 100mm tube is ideal, at the entrance to the machine this would fork into two 50mm tubes, one going directly to the outlet of the circular and the other to the hollow of the machine.

These design are for my original Saw & Router Table, for Routers with 43mm Clamping Collar and a Makita 5903R Circular Saw, for other tools, you must be make changes surely.

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As can be seen in the video, the cover which also acts as a table is made of 20 mm birch plywood with melamine for both faces. I found this in a carpenter’s shop, but I don’t remember what they said it had been used for, however, when I saw it, I bought it at once  as these are difficult to find for small scale production purposes. Normal, varnished birch would serve perfectly, and this was my first idea. It is screwed underneath and has recesses for a saw and a milling machine, some by the upper face in order to be facilitate changing the disks and cutters easily, others by the lower face in order to adjust the saw to the table and achieve a deeper cut. It has other recesses in the upper part in order to insert the aluminium profile which will act as a guide. I machined all these recesses with a milling machine and guides, this part is very important in order to achieve cuts in set square, all the templates for this milling must be placed straight and squared. My profile measures 15mm wide by 10mm deep, but other measurements can be used, however, with a maximum of 10mm in depth in order not to weaken the table too much. The profile must enter exactly but with no need to force it to enter.

The support for the horizontal milling machine is made from birch plywood and must be hard and stable. The part in contact with the milling machine measures 20mm, the rest measures 12mm. Cut properly straight and squared all the parts so that the milling machine also works in set square. It is meant for milling machines with a 43mm Clamping Collar, so, make this hole very precise. If you cut too excess, the milling machine will remain loose with the logical hazards! Use metric 8mm bolts with threaded inserts.

The vertical support for the milling machine is made of birch, again with a 43mm Clamping Collar. The tightening handles are made of birch plywood and I used metric 8 with their corresponding threaded inserts. Check the length of the milling machine in case the structure is too short and you have to lengthen it a little. The hinges enable you to gyrate the milling machine and take more advantage of it so as to make mouldings or cuts. Use glue and long screws in order to provide resistance to the support.

I have developed this function in order to make joins in boxes or drawers more easily and comfortably. Make an MDF template with 10 mm outlets and inlets. I have made these on my home CNC milling machine, but if you fdo not have one, the best thing to do is to order these templates from someone who does. It is very important that these are perfect so that the system will function correctly. In order to reset the work, as can be seen in the video, you must place the two pieces one in each frame, 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 milling machine and saw function. Beginning the 3D Router project with my home circular, assembling this tool requires extreme precision and quite extensive experience in carpentry work. The cuts must be perfectly straight and squared, the axes must be perfectly parallel so that the ball bearings do not have any play, and are correctly aligned, if this is not so, the tool will undergo 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 domestic vacuum I've been using had not power enough 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 (16)

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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