A simple router-table setup for putting a finished edge on plywood panels.
While building the Kid's Oak Dresser, see link below, project builder Chuck Hedlund had to do a lot of flush trimming on the solid-wood edging that dresses up the plywood panels. He needed a foolproof way to get the job done. A handheld router with a flush-trim bit works, but it’s easy to accidentally tip the router and gouge the edging and plywood. Chuck solved the problem with the router-table-mounted fence shown in the photo, right.
Made of 3/4" plywood, the fence sits perpendicular to the table, as shown below. The lower edge of the fence is mounted 1" above the router-table surface, so it accommodates edging up to 3/4" thick.
To build the project, cut its identically sized fence and base to 11-3/4" wide. Measure your router table to determine the length. Then cut matching notches in the base and fence, positioned to align with the bit hole in your table. Two triangular braces hold the base and fence together. The cleats at each end help position the assembly on your router table.
Chuck also added a support panel to the braces that stiffens the entire assembly. A hole cut into the support accepts a shop-vacuum hose to collect chips.
To use the fence, install a flush-trim bit in your table-mounted router. Align the fence face flush with the bit's pilot bearing, and clamp the fence down. Hold the edged plywood firmly against the fence as you make each pass, and the edging comes out perfectly flush every time.
Written by: David Stone
Project design: Chuck Hedlund
Illustrations: Roxanne LeMoine
Photograph: Marty Baldwin
If you like this project, please check out the hundreds of shop-proven paper and downloadable woodworking project plans in the WOOD Store.