I base my design on this free plan found here.
Basic requirements
1. Reasonable size to clamp to existing workbench
2. Simple pivoting fence that is square
First, I cut a 9mm thick plywood to some reasonable size. Then I find the center by drawing lines corner to corner.
Punching a dent at the center to guide the drill bit.
Choose a hole saw to cut out a hole to fit my biggest router bit. I didn't have a 35mm hole saw so I chose the next size up.
Cut out the hole. Put a sacrificial board underneath to reduce tearout.
Using the router base plate, center it on the hole and trace out the mounting screw locations.
Then, punch guide dents.
Measure router screw dimensions. I need a 4mm hole, countersunk to fit 8mm flat head.
Drill and countersink and test fit the screws.
Sand of the bottom side where the router base will be mounted. This is important so that the router base can be mounted flush to the bottom surface.
Mounting the router base demonstrates Murphy's Law in action. Ooops! Router base has a tab and can't be mounted flush - need to chisel out a slot.
Chisel out a slot to fit the router base tab, and mount the router flush. Test it on the workbench.
Nope.. Need to be mounted horizontally to fit the workbench gap.
Find a fence - a piece of MDF cut from previous project. Drill a hole for the pivot, and fix it to the table.
Looks ok.
Cut out a hole in the fence by just rotating the fence about the pivot, into the router blade. Then give it a test route on a scrap piece of wood.
Close up of hole in the fence
Works well. Cuts straight and square. In all, quite a successful build. Spent about 5 hours building this.
More pics. Front view.
Side view.
