I’ve got a nice , big Rousseau router table that I’ve decided to put a Jessem Mast-R-Lift into. The only problem is that the existing cutout on the table is 1/4″ wider than the Jessem plate. I’m going to center the lift plate, and that will leave me with a 1/8″ gap on either side. I’m looking for suggestions on how to best fill the gaps. I thought of either building them up a little more than I need with epoxy and then routing to size, or cutting out two wood filler strips, gluing and clamping, and then routing them to size. The void areas I have to fill are 1/8″ wide, 1/4″ deep, and 9-1/4″ long, and the ends are radiused. The table is MDF that’s about 1-1/8″ thick, with a melamine-like top and bottom surface. I haven’t used epoxy for something this size before. I’d appreciate any comments on what you think of these two ideas…or others. Thanks.
Edited 12/5/2003 2:52:06 PM ET by ghaselbe
Replies
Ghasebel, Using a hand held router and a 1/2" straight carbide router bit, enlarge the original four sides of the tables hole so you can glue inserts to effectively close up the opening.
By making and taping a square ''Picture frame'' template equally spaced around the opening, routed from 1/4" stuff (to the correct dimensions,) and rimmed with a raised border, you can cut out the rabbet first.
Then with 4 filler strips to shift over the cut, rout the through cut. The pieces of oak that you will rabbet and miter and glue to the new enlarged hole should be oversized enough to allow enough 'meat' for the final routing of the new rabbeted 'Surround'
The original template should be taped in place all the while and just the correct filler spacer strips added as the job progresses. and the hole shrinks Stein.
Edited 12/5/2003 4:38:32 PM ET by steinmetz
Edited 12/5/2003 4:42:08 PM ET by steinmetz
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