Best non-wood material for large router base

[Bruce Cohen]

I need to construct a larger clear (much) router base for my Dewalt 618 plunge. I can't remember what's the best material to use (Lexan, phenolic?). I know plex shatters, so I guess that's out.

Suggestions???

Many Thanks,

Bruce

[LCHIEN]

I don't think phenolic comes in clear.
I'd use lexan (polycarbonate) or Plexiglas (Acrylic).
A router base should not see high impact... Plexiglas might work fine.
lexan costs more and is a bit harder to come by.
I think they work (machine) about the same.

[LarryG]

Pat Warner uses acrylic for his after-market sub-bases, some of which he supplies (or used to: might not still) to Porter-Cable to be sold under their name.

[cabinetman]

I've always used just 1/4" clear Plexiglas (cast acrylic), and on occasion polycarbonate (Lexan). Polycarbonate can shatter, DAMHIKT. Only in rare situations have I used anything thicker than 1/4". When countersinking for heads, do so very slowly as not to chunk out the hole or break through and make a larger hole. A four fluted carbide tipped counter sinker works very well.
.

[jon_ramp]

I bought 220 plexiglas at Home Depot. It’s about 1/32 shy of ¼ thick. I cut an 8" square with a 2.5 inch center hole. Put it on the fixed base of my DW618 so that I could mount it to the accessory table of a BT Craftsman with folding base. Works fine so far.

[Uncle Cracker]

I've made 'em for myself and others out of Plexi... No complaints thus far... Just don't crank down hard on the screws, and try not to have any holes too close to an edge.

[gwyneth]

Don't laugh too hard, but a great source of clear plastic for this use is some plastic clipboards--cheap, sturdy, three sides already square. I made a very nice lavender one, as well as a pink one that's been used on the one or two occasions over the years where I've needed to keep a router on a job site.

They do also come in colorless.

[niki]

Hi Bruce

And I'm using....Floor panel....8mm (5/16") HDF, covered with Formica on both sides, very slippery, 15 years guaranty for walking on it...

After you drill the mounting bolts holes, put Super glue on the hole counter-sink and the hole itself and let it dry (penetrate) for 10~15 minutes, the counter-sink and the hole will become "iron".

As you can see, It's not limited only to the router...

Best Regards
niki