My SIL Steve - a luthier - wanted an overhead router for some of his work. He also wanted to be able to follow templates using a small bearing fixed to the table and coaxial to the router.
He suppplied the router and worked with me designing the machine to match his work envelope - and 'stuff' I had sitting around.
I had a heavy cast iron vertical column that I had no use for which looked the part and he agreed. So searching for a base, I came across an odd sized heavy-walled RHS 140mmx40mm. Add some outrigger feet and it would bolt to Steve's work bench well. Discussing the table requirements, I spotted a heavy ribbed aluminium base which came from GregQ's stocks when he moved. It appears to be Nickel plated and looked the part to both Steve and me.
So fabricating the base and the router mount was really what it boiled down to.
I turned up a couple of threaded bushes to weld into through holes of the base to bolt the heavy column down solid. The section of the base was thick enought to drill and tap suitable bolt holes for table.
So once the welding was done on the base, I levelled the base on my surface grinder.
Fabricating the router mount was a little more time intensive. I wanted it rigid and had some 50x16mm flat steel to suit and went about cutting and welding that up, trying to keep things aligned and at right angles as needed. I then surface ground the mounting side flat and the router attachment face at right angles. Then drilled a couple of holes for some turned pegs to fit into the router (where it's 'normal' table would be fitted) and welded these into holes drilled in the attachment wich by now was pretty massiv.
We trial assembled the whole thing and using a pointy router bit pilot dilled the table bearing position in situ. A standard router bit bearing (the little bearings some of them have on the end) was then fitted to the table with a little cutom coutersunk shoulder screw.
Testing it out on a bit of wood showed that it was nice and rigid and quite easy to use.
So it was all disassembled, cleaned, sanded, primed and 2K coated in 'Waldown turquoise' to match the Waldown I restored for him (ex azzrock) a few months ago.
I'll take a photo of the two side-by side when he's installed it.
Here are some photos of the progress:
IMAG1681.jpg IMAG1682.jpg IMAG1683.jpg IMAG1684.jpg IMAG1685.jpgIMAG1689.jpg IMAG1686.jpg IMAG1687.jpg IMAG1688.jpg IMAG1691.jpg IMAG1692.jpg IMAG1698.jpg IMAG1699.jpg IMAG1700.jpg IMAG1701.jpg IMAG1702.jpg
He suppplied the router and worked with me designing the machine to match his work envelope - and 'stuff' I had sitting around.
I had a heavy cast iron vertical column that I had no use for which looked the part and he agreed. So searching for a base, I came across an odd sized heavy-walled RHS 140mmx40mm. Add some outrigger feet and it would bolt to Steve's work bench well. Discussing the table requirements, I spotted a heavy ribbed aluminium base which came from GregQ's stocks when he moved. It appears to be Nickel plated and looked the part to both Steve and me.
So fabricating the base and the router mount was really what it boiled down to.
I turned up a couple of threaded bushes to weld into through holes of the base to bolt the heavy column down solid. The section of the base was thick enought to drill and tap suitable bolt holes for table.
So once the welding was done on the base, I levelled the base on my surface grinder.
Fabricating the router mount was a little more time intensive. I wanted it rigid and had some 50x16mm flat steel to suit and went about cutting and welding that up, trying to keep things aligned and at right angles as needed. I then surface ground the mounting side flat and the router attachment face at right angles. Then drilled a couple of holes for some turned pegs to fit into the router (where it's 'normal' table would be fitted) and welded these into holes drilled in the attachment wich by now was pretty massiv.
We trial assembled the whole thing and using a pointy router bit pilot dilled the table bearing position in situ. A standard router bit bearing (the little bearings some of them have on the end) was then fitted to the table with a little cutom coutersunk shoulder screw.
Testing it out on a bit of wood showed that it was nice and rigid and quite easy to use.
So it was all disassembled, cleaned, sanded, primed and 2K coated in 'Waldown turquoise' to match the Waldown I restored for him (ex azzrock) a few months ago.
I'll take a photo of the two side-by side when he's installed it.
Here are some photos of the progress:
IMAG1681.jpg IMAG1682.jpg IMAG1683.jpg IMAG1684.jpg IMAG1685.jpgIMAG1689.jpg IMAG1686.jpg IMAG1687.jpg IMAG1688.jpg IMAG1691.jpg IMAG1692.jpg IMAG1698.jpg IMAG1699.jpg IMAG1700.jpg IMAG1701.jpg IMAG1702.jpg
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