Easy Steps to Installing a Router Extension On Your Table Saw

Several companies sell router table extension wings. Woodpeckers Inc. is one of these companies. Using their versions of the router table extension wings as an example, you can see how easy it is to add this helpful addition to your table saw.

In our example, you will install the router extension table on the left side of your table saw. Other models may require a different configuration, but the process will essentially be the same. Made of 1" thick MDF laminated on both sides with a matte white high pressure laminate which brings the final thickness to 1 1/8th inches, the extension table is 21"x28". The router extension table also has a white plastic edging. In this particular model, the mounting package includes four brackets to mount the router extension table wing to the rails, phenolic insert with four aluminum spacer rings, stiffener rails, hardware and instructions. Installing the extension table is easy enough that it should not take you more than an hour to finish.

Step 1

Remove the left wing of your table saw.

Step 2

After removing the existing table wing, you are going to mount the router table extension wing brackets to the rails per the instructions using the supplied T-nuts. Use the larger washers provided for this step. Put the T-nuts and washers together and slide four sets into the channel on both the front and back rails. You can then slip the brackets onto the hardware behind the washers.

Step 3

Line the outer brackets up with the end of the rail and snug the nuts down but do not completely tighten them. The inner brackets should be positioned about 2" from the saw table and also snugged down but not tightened. You do not want them completely tightened since they may have to be moved left or right to avoid interference with the stiffeners or to level the table.

Step 4

The insert cutout is going to be off-centered in the table. Flip the table upside down on the brackets with the widest part of the insert offset to the left or outside of the saw. Put one stiffener bar about an inch from the left side of the table and drill pilot holes for the screws. A helpful hint is to use blue tape on the drill bit to set the depth of the holes to make sure that you go all the way through. After drilling the pilot holes, you can screw down the stiffener. Repeat this process for the other stiffener placing it about an inch or so to the outside of the left edge of the insert cutout.

Step 5

If necessary, adjust the bracket or stiffener placements to avoid interference. After this is done, turn the table back over.

Step 6
Next, you will attach the brackets to the bottom of the table. Drill a pilot hole first and secure each bracket with just one screw. Before finishing, make sure the brackets and stiffeners don't interfere with each other and then finish the bracket installation.

Step 7

Now, it is time to position the table and brackets. Using a rule, set the table level front and back to the saw's table. Also check that the router extension table is flush up against the table saw.

Step 8

If the table is not exactly flat or sags, loosen the middle screw on the stiffener and insert a spacer. The space could be a piece of card stock that is the size of the sag. Once the screw is tightened again. The spacer will make the table flat.

Step 9

Now, it is time to put in the insert. The 3/8" black phenolic insert sits on a rabbet in the MDF tabletop. To level the insert in the opening, it has 8 leveling setscrews. You can adjust each one a little bit at a time going back and forth between all the screws until the insert is level and stable.

Step 10

This particular brand, Woodpecker, will pre-drill the mounting holes in the insert according to which router you tell them you will be mounting. Using the screws they provide, you now just mount your router to the insert on the router extension table.

This is just one option for a router extension table. You particular table saw may have a specific router extension table sold as an accessory. Whether you buy yours from Woodpecker or as an accessory, attaching the router extension table will offer you convenience in your woodworking shop.

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