Here's a project that I've had on the back burner for several years. Finally getting "to it". This is my Norm Abram New Yankee Workshop deluxe router table. As noted below, parts were purchased 2 years ago. I've never worked with MDF before, so was pleasantly surprised at how well it cuts and works. Sure is dusty though. This project has gone very well. One slight goof, on the last operation I was doing on the top, I decided (wrongly) to cut the dado that runs the length of the top in front of the router using the dado in the table saw. The result was slight chiping of the laminate along the final edge of the dado. I had debated whether to use the router or the saw and should have picked the router. Oh well, a couple of little spots with some gray paint to match the laminate and they'll pretty much disappear. Too lazy at this point to start all over on another top. All the drawers fit real nice and work smooth with an even reveal around each drawer front. Really happy over all. This is a heavy solid table design with plenty of storage and I'll never wear it out.

Construction notes:

8/6/2004 Purchased "Deluxe Router Station Plan" from NYW. ($16)

9/15/2004 Purchased "NYW router table kit" and PC890 router plate from Rockler. ($120)

9/23/2004 Purchased "PC895PK" router and 3-18" ball drawer slides from Woodworker's Supply. ($317)

8/16/2006 Purchased plywood materials. ($188)

8/16 Sawed parts from 3/4" stain grade birch, 3/4" MDF, and 1/4" stain grade birch.

8/16 ---4-1/2 hrs shop time---

8/17 Sawed parts from 1/2" stain grade birch.

8/17 Glued and screwed together 2 MDF pieces for top.

8/17 Cut fence bit port and angles, cut fence base dust port and angles, 1/4" round-over edges on both.

8/17 ---3 hrs shop time---

8/21 Cut fence brace blocks.

8/21 Cut fence dust collector frame.

8/21 1/4" roundover on brace block edges, light sanded all parts.

8/21 Assembled base fence parts.

8/21 Cut 3/8" dado to start T-slots in adjustable fence pieces.

8/21 Cut 3/4" dado in fixed fence piece for metal T-slot.

8/21 Cut rabbets and dados in cabinet sides.

8/21 Cut dados in bottom and middle shelves.

8/21 Cut dados and rabbets on drawer fronts and dados on drawer sides for drawer backs.

8/21 Purchased Laminate for top, red oak for trim, 2" PVC TY for dust fitting and 2-1/2" dust collection hose. ($136)

8/21 ---5 hrs shop time---

8/22 Ordered laminate.

8/22 Cut dados in drawer front, sides and backs for 1/4" bottoms.

8/22 Dry fit 3 large drawers.

8/22 Cut toe kick notches at bottom/front of cabinet side panels.

8/22 Cut vertical drawer divider piece to size.

8/22 Cut top cleat notches at top/front of vertical interior panels.

8/22 Cut toe kick blocks, glued and nailed on inside bottom edges of side panels.

8/22 Assembled case less vertical interior panels.

8/22 Fastened drawer cleats using 1-1/16" spacer block to side panels and vertical interior panels.

8/22 Assembled vertical interior panels inside case.

8/22 ---5 hrs shop time---

8/23 Assembled dust chute.

8/23 Built 2" PVC vacuum fitting.

8/23 Installed top 3/4" x 3/4" cleats inside case.

8/23 Assembled, glued and clamped 3 large drawers.

8/23 Mounted Rockler On/Off switch in false front panel. (Did this instead of side mount shown on drawing.)

8/23 Cut red oak 1 x 2 wrap to fit top, cut biscuit slots, glued and clamped.

8/23 ---8 hrs shop time---

8/24 Glue red oak edging on front case plywood edges. (about 80% complete)

8/24 Routed T-slots in adjustable fence pieces.

8/24 Angled top edge of fixed T-track fence.

8/24 1/8" roundover on large drawer edges and sanded with 220.

8/24 1/8" roundover on bit drawer fronts and sanded with 220.

8/24 ---4 hrs shop time---

8/25 Completed red oak edging on front case plywood edges.

8/25 1/8" roundover and sanded all red oak edging on case front.

8/25 ---1 hr shop time---

8/26 Cut door frame pieces and mitered.

8/26 1/8" roundover on door frame edges.

8/26 Cut 3/16" dado 5/16" deep on inside of door frame pieces.

8/26 Cut 3/16" plexiglass panel.

8/26 Bored three 1" air flow holes along lower edge of plexiglass door panel.

8/26 Drilled and countersink #6 x 1" screws at each door frame corner.

8/26 ---4 hrs shop time---

8/28 Mounted door hinges and magnetic catch on door.

8/28 Drilled router bit storage drawers (two for 1/4" bits and two for 1/2" bits).

8/28 Glued and clamped router bit storage drawer fronts.

8/28 Mounted slides for large storage drawers.

8/28 Drilled and mounted knobs for large storage drawers and wrench drawer.

8/28 Brad nailed 1/4" bit storage drawer bottoms.

8/28 Added rubber stop for wrench drawer.

8/28 Drilled and mounted knobs on all storage bit drawers.

8/28 ---7-1/2 hrs shop time---

8/29 Made mounting for false front/switch panel.

8/29 Completed red oak facing on rear case plywood edges.

8/29 ---1 hr shop time---

8/30 Cut laminate pieces to rough oversize.

8/30 Glued laminate on fence parts. Used Titebond water base contact cement, very good.

8/30 Glued laminate on top.

8/30 Routed edges on all laminated parts.

8/30 ---2 hrs shop time---

8/31 Routed fence adjust slots in top.

8/31 Cut router openning in top.

8/31 Routed 1/2" wide by 1/4" deep recess for router base plate.

8/31 Sanded 1/2" radius on corners of top.

8/31 Routed 45 degree bevel on top edges, both top and bottom.

8/31 Cut dado 1" wide by 1/2" deep for track. Used table saw, chipped laminate slightly on last pass.

8/31 Drilled top for router base plate leveling screws and installed screws.

8/31 Cut 3" square blocks for mounting top and installed blocks.

8/31 Fastened fixed fence to base fence and fastened T-track with 5 screws into base fence.

8/31 ---6-1/2 hrs shop time---

9/01 Bore cord cutouts.

9/01 Bore port for dust collection.

9/01 ---1 hr shop time---

9/02 Made and glued door knob in place.

9/02 Made 2" PVC pipe to 3" dust collector hose fitting.

9/02 ---1 hr shop time---

9/04 Final cleanup sanding and prepped for finish.

9/04 Applied first coat of clear polyurethane finish to all exterior surfaces.

9/04 ---3-1/2 hrs shop time---

9/05 Light sanding with 320 to prep for second finish coat.

9/05 Applied second coat of clear polyurethane finish to all exterior surfaces.

9/05 Prep and glued dust port fitting in case back.

9/05 ---3 hrs shop time---

9/06 Light paste wax on bit drawers and runners.

9/06 Put card holders on bit drawers.

9/06 Glued door frame and installed door.

9/06 Completed fence dust fittings and installed dust hose.

9/06 ---3 hrs shop time--- ***63 hrs total shop time so far***

x/xx Make mounts for casters. This may or may not happen. Can't make up my mind on a solid mounting.